Iocl Summer Training

Indian Oil Corporation Ltd.
Company History The Indian Oil Corporation Ltd. operates as the largest company
in India in terms of turnover and is the only Indian company to rank in the Fort
une "Global 500" listing. The oil concern is administratively controlled by Indi
a's Ministry of Petroleum and Natural Gas, a government entity that owns just ov
er 90 percent of the firm. Since 1959, this refining, marketing, and internation
al trading company served the Indian state with the important task of reducing I
ndia's dependence on foreign oil and thus conserving valuable foreign exchange.
That changed in April 2002, however, when the Indian government deregulated its
petroleum industry and ended Indian Oil's monopoly on crude oil imports. The fir
m owns and operates seven of the 17 refineries in India, controlling nearly 40 p
ercent of the country's refining capacity.
IndianOil Major Projects
IndianOil continues to lay emphasis on infrastructure development. Towards this
end, a number of schemes have been initiated with increasing emphasis on project
execution in compressed schedules as per world benchmarking standards. Schemes
for improvement and increased profitability through debottlenecking / modificati
ons / introduction of value added products are being taken up in addition to gra
ssroots facilities. Project systems have been streamlined in line with ISO stand
ards.
1) GRASSROOTS REFINERY PROJECT AT PARADIP (ORISSA) 2) RESIDUE UPGRADATION AND MS
/HSD QUALITY IMPROVEMENT PROJECT AT GUJARAT REFINERY 3) NAPHTHA CRACKER AND POLY
MER COMPLEX AT PANIPAT (HARYANA) 4) MS QUALITY UPGRADATION PROJECT BARAUNI REFIN
ERY (BIHAR) 5) MS QUALITY UPGRADATION PROJECT AT GUWAHATI REFINERY (ASSAM) 6) MS
QUALITY UPGRADATION PROJECT AT DIGBOI REFINERY (ASSAM) 7) DADRI-PANIPAT R-LNG S
PUR PIPELINE 8) PANIPAT REFINERY EXPANSION FROM 12 MMTPA TO 15 MMTPA 9) BRANCH P
IPELINE FROM KSPL, VIRAMGAM TO KANDLA 10) DIESEL HYDRO-TREATMENT (DHDT) PROJECT
AT BONGAIGAON REFINERY (ASSAM) 11) MS QUALITY UPGRADATION PROJECT AT BONGAIGAON
REFINERY (ASSAM) 12) PARADIP-NEW SAMBALPUR-RAIPUR-RANCHI PIPELINES 13) DE-BOTTLE
NECKING OF SALAYA-MATHURA CRUDE PIPLEINE 14) INTEGRATED CRUDE OIL HANDLING FACIL
ITIES AT PARADIP
Down the memory lane

1958 1959 1960
Indian Refineries Ltd. formed in August with Mr. Feroze Gandhi as the Chairman.
Indian Oil Company Ltd. established on 30th June 1959 with Mr. S. Nijalingappa a
s the Chairman. MV Uzhgorod carrying the first parcel of 11,390 tonnes of Diesel
for IndianOil docked at Pir Pau Jetty in Mumbai on 17th August 1960. Agreement
for supply of Kerosene and Diesel signed with the then USSR Construction of Bara
uni Refinery commenced Barauni Refinery commissioned Indian Refineries Ltd. merg
ed with Indian Oil Company with effect from 1st September, 1964, and Indian Oil
Company renamed as Indian Oil Corporation Ltd. Haldia Barauni product pipeline c
ommissioned. 1965 Barauni-Kanpur product pipeline and Koyali- Ahmedabad product
pipeline commissioned Haldia-Barauni crude oil pipeline completed.
1962 1964
1967
1998
BARAUNI REFINERY
Barauni Refinery was built in collaboration with Russia and Romania. Situated 12
5 kilometres from Patna, it was built with an initial cost of Rs 49.40 crore. Ba
rauni Refinery was commissioned in 1964 with a refining capacity of 1 Million Me
tric Tonnes per Annum (MMTPA) and it was dedicated to the Nation by the then Uni
on Minister for Petroleum, Prof. Humayun Kabir in January 1965. After de-bottlen
ecking, revamping and expansion project, it's capacity today is 6 MMTPA. Matchin
g secondary processing facilities such Resid Fluidised Catalytic Cracker (RFCC),
Diesel Hydrotreating (DHDT), Sulphur Recovery Unit (SRU) have been added. These
s state of the art eco-friendly technologies have enabled the refinery to produc
e environment- friendly green fuels complying with international standards. Indi
anOil is the highest ranked Indian company in the prestigious Fortune 'Global 50
0' listing, having moved up 19 places to the 116th position in 2008. It is also
the 18th largest petroleum company in the world.
Awards/Accolades
Barauni Refinery achieved safety award in gold category of Green Tech Foundation
Safety Award on 04.05.09.
BR bagged 2nd prize in Golden Jubilee Indian Oil Album
in Aug 09. Barauni Refinery accredited in Oct 09 with prestigious Jawaharlal Nehr
u Centenary
Awards (3rd prize) for Energy Performance in Refinery for the year 20
08-09 by MoPNG. o Suggestion Fortnight declared and inaugurated by ED, BR on 09.
12.09. o Barauni Refinery has been accredited first prize in the refinery sector
for National Energy
Conservation Awards-2009 by Ministry of Power. Award received
by ED, BR on 14.12.09. Barauni Refinery was initially designed to process low s
ulphur crude oil (sweet crude) of Assam. After establishment of other refineries
in the Northeast, Assam crude is unavailable for Barauni . Hence, sweet crude i
s being sourced from African, South East Asian and Middle East countries like Ni
geria, Iraq & Malaysia. The refinery receives crude oil by pipeline from Paradip
on the east coast via Haldia. With various revamps and expansion projects at Ba
rauni Refinery, capability for processing high-sulphur crude
has been added high-sulphur crude oil (sour crude) is cheaper than lowsulphur cr
udes thereby increasing not only the capacity but also the profitability of the
refinery. Crude oil is separated into fractions by fractional distillation. The
fractions at the top of the fractionating column have lower boiling points than
the fractions at the bottom. The heavy bottom fractions are often cracked into l
ighter, more useful products. All of the fractions are processed further in othe
r refining units. Different boiling points allow the hydrocarbons to be separate
d by distillation. Since the lighter liquid products are in great demand for use
in internal combustion engines, a modern refinery will convert heavy hydrocarbo
ns and lighter gaseous elements into these higher value products. Oil can be use
d in a variety of ways because it contains hydrocarbons of varying molecular mas
ses, forms and lengths such as paraffins, aromatics, naphthenes (or cycloalkanes
), alkenes, dienes, and alkynes. While the molecules in crude oil include differ
ent atoms such as sulfur and nitrogen, the hydrocarbons are the most common form
of molecules, which are molecules of varying lengths and complexity made of hyd
rogen and carbon atoms, and a small number of oxygen atoms. The differences in t
he structure of these molecules account for their varying physical and chemical
properties, and it is this variety that makes crude oil useful in a broad range
of applications. Once separated and purified of any contaminants and impurities,
the fuel or lubricant can be sold without further processing. Smaller molecules
such as isobutane and propylene or butylenes can be recombined to meet specific
octane requirements by processes such as alkylation, or less commonly, dimeriza
tion. Octane grade of gasoline can also be improved by catalytic reforming, whic
h involves removing hydrogen from hydrocarbons producing compounds with higher o
ctane ratings such as aromatics. Intermediate products such as gasoils can even
be reprocessed to break a heavy, longchained oil into a lighter short-chained on
e, by various forms of cracking such as fluid catalytic cracking, thermal cracki
ng, and hydrocracking. The final step in gasoline production is the blending of
fuels with different octane ratings, vapor pressures, and other properties to me
et product specifications.
HIGHLIGHTS
Barauni Refinery achieved highest ever crude processing of 6.2 MMT (o
utlook) during the year. Previous best was 5.94 MMT during the year 2008-09.
Ach
ieved highest ever Low Sulphur crude processing of 5.55 MMT (outlook) during the
year surpassing the previous best of 5.16 MMT during the year 2008-09.
Achieved
highest ever CRU throughput of 288.3 TMT (outlook). Previous best was 277 TMT d
uring the year 1999-00.
Achieved highest ever RFCCU throughput of 1.497 MMT (outlook) during the year su
rpassing previous best of 1.454 MMT during the year 2008-09.
Annual Production (Outlook for the year 2009-10) Product Qty (TMT) Previous best
(TMT) LPG 291.8 284.5 (2008-09) MS (Total) 763.3 703.2 (2008-09) SKO 954.6 894.
3 (2005-06) HSD (Total) 3119.7 3087.7 (2008-09) RPC 207.8 176.9 (2007-08) FO 26.
9 ATMOSPHERIC AND VACUUM DISTILLATION UNIT (AVU-I / II)
INTRODUCTION
There are two Atmospheric and Vacuum Distillation Units in Barauni
Refinery numbered as AVU-I and AVU-II, each were designed for 1 MMT/year crude p
rocessing. Subsequently another distillation unit without vacuum distillation fa
cility was added. This unit was designed for 1 MMT/year of crude and known as AU
-3. Crude Processing capacity of both units AVU-I & AVU-II was increased to 1.6
MMT/year by HETO project (Heat Exchanger Train optimization) in 1990. The above
modification (HETO project job was designed by EIL (Engineer's India Limited) an
d fabrication/erection job was completed by M/s. PETHON ENGG. LTD, Mumbai. The u
nits were again revamped in 1998 (M & I) when the capacity was expanded to 2.1 M
MT/year of each of the two units.
Through these units were designed on the basis
of evaluation data of Naharkatiya crude, presently the units have switched on t
o imported crude due to none availability of Assam crude.
PROCESS DESCRIPTION
Crude oil (imported) is received from Haldia by pipeline and is pumped from tank
s through Heat Exchangers after exchanging heat with various hot stream, the cru
de streams attain a temperature of approx. 120oC to 130oC.
After attaining tempe
rature about 120oC to 130oC the two crude flows combine together and enter in De
salter for separation and removal of water and salt. Bi electric desalter is hav
ing two energised electrodes. A distributor head splits crude between the upper
and lower pair of electrodes. Crude oil separated from water between the centre
and lower electrodes passes through the upper electrode in a converging counterc
urrent flow with the separating water from upper set of electrodes. This creates
a second washing zone for half of the feed in a strong electrical field thereby
causing maximum salt removal efficiency. The two desalter in AVU-I &II are PETR
ECO BIELECTRIC type which were commissioned in the year 2001.
POST DESALTER:- At
the outlet of Desalter there are two booster pumps which boost up the crude at
discharge pressure around 15 kg/km2 . Pre-topping column has 20 Trays (All valve
trays with a bed of packing between 9th & 10th tray) and operates operating con
ditions
Present Pressure Kg/cm (g) Top temperature (Deg. C) Bottom temperature (Deg. C) 2
.4 112 118 210 to 215 As per design 4.0 120 240
Pretopped crude stream passes through heat exchangers. After exchanging heat wit
h various hot products the pretopped crude flows combine and it is segregated ag
ain near furnace in two pass flows before entering the atmospheric heater for fu
rther heating and finally fed to 6th tray of main column through two entry nozzl
es at 340oC.The Furnace is provided with Air Preheater.
Main Fractionating Colum
n has 43 double pass valve trays. Following are the operating parameters of the
main column. Present
Pressure Kg/Cm(g) Top temperature oC Bottom temperature oC 0.3-0.5 115 330
As per design
0.8 130 330
As per design two types of gas oil, one light and other heavy were supposed to b
e withdrawn light gas oil from 6th and 18th tray and heavy gas oil from 8th/10th
trays at 140-300oC and 300-350oC respectively. At present gas oil is withdrawn
as 250-370oC cut from 16th/18th tray. The existing 7th to 14th double pass chann
el trays were replaced with valve trays in HETO,1990. Since 1970 heavy gas oil w
ithdrawal was stopped. Main Column bottom is feed to vacuum column . VACUUM DIST
ILLATION :- Vacuum distillation is a method of distillation whereby the pressure
above the liquid mixture to be distilled is reduced to less than its vapor pres
sure (usually less than atmospheric pressure) causing evaporation of the most vo
latile liquid(s) (those with the lowest boiling points). This distillation metho
d works on the principle that boiling occurs when the vapor pressure of a liquid
exceeds the ambient pressure. Vacuum distillation is used with or without heati
ng the solution.
Vacuum distillation increases the relative volatility of the key components in m

any applications. The higher the relative volatility, the more separable are the
two components; this connotes fewer stages in a distillation column in order to
effect the same separation between the overhead and bottoms products. Lower pre
ssures increase relative volatilities in most systems. A second advantage of vac
uum distillation is the reduced temperature requirement at lower pressures. For
many systems, the products degrade or polymerize at elevated temperatures. Vacuu
m distillation can improve a separation by:
Prevention of product degradation or polymer formation because of reduced pressu
re leading to lower tower bottoms temperatures, Reduction of product degradation
or polymer formation because of reduced mean residence time especially in colum
ns using packing rather than trays. Increasing capacity, yield, and purity.
Another advantage of vacuum distillation is the reduced capital cost, at the exp
ense of slightly more operating cost. Utilizing vacuum distillation can reduce t
he height and diameter, and thus the capital cost of a distillation column.
Reduced crude from main column bottom at a temperature of approx. 330oC is pumpe
d through Furnace. The Furnace coil outlet (4 passes) combines in one header and
enter into vacuum column at 4th plates through two entry nozzle. Coil outlet te
mperature is maintained at about 380oC. Operating condition of Vacuum Column are
as follows :
Attributes Pressure, mm of Hg abs Top Temp.o C Bottom Temp o C Present 60 60 345
As per Design 60 100 385
Coil outlet temp o C
380
420
STABILIZER COLUMN:-Unstabilised gasoline is pumped to 16th/20/24th tray of Stabi

liser. Feed temperature is about 110oc. The column has 35 valve trays. Operating
conditions of Stabiliser are:Pressure Top temperature Bottom temperature 8.0 Kg
/cm 60C 150oC
. LPG CAUSTIC WASH:LPG caustic wash facilities were provided in AVUII and was fi
rst commissioned in Sept,1984 where LPG of AVUI, AVU-II is washed with caustic so
lution of 10-12%, strength.
Heavy Naphtha is drawn from main column ,36th tray,
through stripper. Operating parameters
Top Temp. Top Pressure Heavy Naphtha withdrawal rate 90 Deg celsius 0.3 kg/cm (g)
8 9 M/hr
Product Streams Ex AVU-I/II
Streams
LPG E1 Gasoline E2 Gasoline Heavy Naptha MTO SK Mixed Gas Oil 1st CR
Distln. (Deg C) W= +2 max. FBP = 110 130 FBP <= 165 FBP <= 210 FBP <= 205 FBP <=
280 95% = 370 (max.) >35 >35
Flash (deg. C)
Pour (Deg. C)
<=3 0-30
Wide Cut Short Residue

>150 >150
TEMPERED WATER FACILITIES: (HETO - 1990) During HETO, tempered water facility wa
s provided in AVU-2 . Tempered water is used as cooling media in S.R. cooler ins
tead of Pressurised cooling water as is being used in conventional coolers. This
facility is common for both AVU-1 & AVU-2. Tempered water is steam condensate,
received from condensate recovery system of refinery, with neutral ph value afte
r chemical treatment. Use of tempered water in cooler prevents the sealing and c
orrosion in cooler tubes thus ensuring the very efficient cooling of product (S.
R.) and minimising to a great extent the maint. of the cooler. Tempered water fa
cility is essentially a closed circulating system in which the loss of tempered
water during circulation is very negligible.
CORROSION CONTROL:- Ammonia is inje
cted in the form of aquous solution for preventing HCL corrosion in pretopping a
nd main column overheads. Recent modification of this system is the installation
of on line pH meters for measuring pH in both the units.
AHURALAN INJECTION:- A
huralan is the trade name of an organic inhibitor compound, used for preventing
corrosion of condenser shell. It prevents corrosion by forming a thin protective
layer on the equipment. A 5% W/V and 2% W/V solutions are prepared in AVU-I and
AVU-II respectively. Injection rate in both the units is 5 PPM of overhead cont
ents.
MAJOR EQUIPMENT
TUBULAR FURNACES
Tubular furnace is cylindrical type for pretopping and vacuum sections. It is bo
x type for the main distillation column.
The furnaces have sections called "Radi
ation Section" and convection section. A part of the tube in convection zone is
for super-heating steam( used in the process) and the rest is used for heating t
he oil in tubes. The inside walls of the furnace are protected against the tempe
rature effects by a refractory insulation to reduce the outside heat losses.
The
bottom bed show openings in which burners are placed. The flue gases go out of
the furnace thorough the stack.
The stack is protected inside, in its lower part where the flue gases are still
very hot by a wall of refractory bricks. A damper is located at its base to allo
w the regulation of the draft. This damper is built with steel suitable for the
flues gases temperature. BURNERS
The burner is conceived to burn either gas or o
il. Gas burners are of two types: either with pre-mixing or without premixing. I
n the first type a part of the combustion air is mixed with the fuel gas before
this has reached the injector nozzle of the burner. The burners without premixin
g give a diffusion flame, the combustion air entering the furnace in a parallel
direction with the gas jet and slowly diffusing in it. AVUs gas burners are of t
his type. They give a longer and more luminous flame than those with premixing.
AVUs burners are of inside-mix type. In these, the steam and oil are mixed in a
chamber within the burners, and they issue together from the burner as a single
stream. Foam formed in the mixing chamber is directed by the shape and direction
of the burner tip so that the flame is of proper shape and size for the furnace
box.The burners with spraying by steam have a flexibility much higher than thos
e with mechanical spraying.
ATMOSPHERIC AND VACUUM DISTILLATION UNIT III
THE PROCESS
Crude preheat
Crude is pumped to desalter through two parallel passes in PreDesa
lter Heat Exchanger Train-1. The first pass consists of four nos. of heat exchan
gers:
The second pass of heat exchangers also has four nos. of heat exchangers:
Both the passes combine in a single header and enter the desalter.
Desalter circuit:-A static Mix valve and a control valve is provided for mixing
water and demulsifier with crude prior to entry into the desalter. The desalter
pressure is controlled at around 9.0 Kg/cm2 (g) The desalted crude is pumped to
Pretopping Column .
Heat exchanger train ii:-The discharge is through a series o
f heat exchangers (6 Nos.). In this network of heat exchangers, crude is heated
by outgoing products to a temperature of around 230 C.
Pretopping column:- The de
salted crude at 230 C enters the columns for withdrawal of unstabilised gasoline a
nd heavy naptha. Heat exchanger train iii:- The bottom product at a temperature
of around 250 C is pumped to furnace through heat exchangers and then after combi
ning is routed in parallel streams through pre-heat exchangers (3 Nos). The preh
eat temperature at the exit is around 270 C. Part of the bottom product coming ou
t of the heat exchanger train is sent to Pretopping Column as heat input. The co
il outlet temperature of the furnace is maintained at around 360 C. Pre topping c
olumn bottom product is sent through the main furnace. The coil outlet temperatu
re is maintained at around 360C.
Main fractionator:-The main column is provided w
ith: Valve trays in the top section,
KERO / LGO section,
Structured packing in L
GO / HGO section,
The bottom stripping section and Over-flash section.
The colum
n bottoms (RCO) is flashed into the Vacuum Column.
Stabiliser section:-Part of the condensed overhead gasoline is pumped through he
at exchanger to stabiliser section.
Lpg caustics wash:-LPG goes to LPG caustic wash-vessel after mixing with caustic
. Vacuum section
The Vacuum column is provided with structured packing in LVGO p
umparound section, LVGO/HVGO fractionation section, HVGO pumparound section, and
Wash section and valve trays in the bottoms stripping section. The column is op
erated at a top pressure of 70 mm Hg.
K-301 top is provided with a demister to m
inimize the entertainment of liquid droplets in the vapour going to overhead-con
denser. The side streams of main vacuum column are as under :
Stream First Second Third Bottom Product LVGO & CR HVGO & CR SLOP & OVERFLASH SH
ORT RESIDUE
This Reboiler Furnace is a vertical cylindrical heater with convection and radia
nt section.
The heater houses 12 nos. of horizontal tubes in convection section
and 48 nos. bare tubes 6" NB of A335 P9 material. These 48 tubes are arranged in
double pass arrangement giving material total radiant heat transfer area of 248
.8 m2. The firing of this heater is done by 4 nos. combination fuel fired forced
draft burners provided with pilot burners having automatic electric ignition sy
stem. Refractory material used in the radiant sanction of this heater is ceramic
fiber blanket.
Crude heater is a vertical cylindrical heater with convection an
d radiant sections.
The radiant section of the heater houses 88 nos. bare tubes
of 6" NB of A335 P9 material. These 88 tubes are arranged in four-pass arrangeme
nt giving total heat transfer area of 856.8 M2.
In the horizontal convection sec
tion there are 24 nos. bare tubes of A335 P9 material and 64 nos. of studded tub
es with an extended surface area of 950 M2. In the convection section, there are
also 12 nos. of extended surface tubes for steam superheat with an extended sur
face area of 70 M2. The firing of this heater is done by 8 nos. combined fuel fi
red forced draft burners provided with pilot burners having automatic electric i
gnition system. Refraction material used in the radiant section of this heater i
s ceramic fiber blanket
Vacuum heater F-301 is a vertical cylindrical heater with convection and radiant
section.
In each pass of the furnace, there is arrangement for introducing turb
ulising steam at convection section inlet and convection section outlet. The rad
iant section of the heater houses 54 nos. bare tube of 6" each NB A335 P9 materi
al. These tubes are arranged in two parallel passes giving total heat transfer a
rea of 330 M2. In the convection section, there are 12 nos. of bare tubes of A33
5 P9 material of total surface area of 34.81 M2 & 44 nos. of studded tubes of A3
35 P9 material of total exposed surface area of 509 M2.
The firing of this heate
r is done by 4 nos. of combined fuel fired forced draft burners provided at the
floor with pilot burners having automatic electric ignition system. Refractory m
aterial used in the radiant section is ceramic fiber blanket.
Air preheater :-Du
ring normal operation, combustion air for all furnaces is supplied by forced dra
ft fans. Air is preheated at 236oC in a common air pre-heater. Air preheating is
based on heat exchange between hot flue gas and combustion air. Hot flue gas le
aving the convection section of the furnaces at 323oC is mixed together before g
oing to shell side of the APH (annular spaces between the finned modules).
The c
ast iron HT/HTA tubes have integral fins on the inside (air) and outside (flue g
as) surfaces.
Air preheater is provided with glass tubes in the lowest pass in o
rder to avoid corrosion due to acid condensation in cold flue gases.
LPG RECOVERY UNIT ( LRU )

CAPACITY / STREAM FACTOR i)Gas and unstabilised naphtha from ACU ii)Gas from exi
sting Coker Unit iii)Stream factor iv)Unit Turndown v)Year of Commissioning 9900
0 Tonnes / Year 93696 320 days 25% 1986 ,, ,,
INTRODUCTION Gases from Coker-A, Coker-B & Stabiliser off-gas from AVU-I / II /
III are compressed in a two stage steam turbine driven compressor. Compressed ga
ses at a pressure of 14.0Kg/cmg along with unstabilised naphtha are cooled to 40C
in air and water cooler successively and fed to a discharge knock-out pot where
gas and condensate (mainly-LPG) are separated. Gases from the knock-out pot are
passed through an absorber column and flow counter to the naphtha and kerosene s
treams in two separate sections respectively. Naphtha absorbs any C3,C4 fraction
s present in the gas. Kerosene further minimises the loss of naphtha entrained b
y the gases. Kerosene is taken from cikers and rich kerosene from this absorber
is fed back to the fractionating column of cokers. Rich naphtha from the lower z
one of the absorber along with the condensate obtained from the compressor disch
arge knock-out drum is preheated by Debutaniser bottom stream and pumped to stri
pper column where light ends ( C1 and C2 ) are stripped off by reboiler vapour a
nd fed back to the inlet of compressor discharge KO drum ( to recover C3 ,C4 , i
f any). Fuel gas from the absorber top goes to a knock-out drum and fed to the r
efinery gas network. Stripper bottom containing mainly LPG and Naphtha
are fed to the Debutaniser column for separation of LPG and Naphtha. LPG is with
drawn from the top reflux drum and stabilised naphtha from the bottom of the deb
utaniser column. A required part of this stabilised naphtha is recycled back to
the absorber as absorbing medium and rest of stabilised naphtha goes as product.
Both LPG and stabilised naphtha products are further washed in caustic soda was
h section separately for removal of any H2S. Products are further passed through
sand filters and then sent to the product storage tanks FEED - STOCK a) Gas fro
m ACU
WT. %
26.28 15.28 4.17 9.29 24.00 7.68 8.56 11.12
c)
Gases from existing Coker
COMPONENT Methane WT. % 25.7 18.9 17.7 8.6 1.
COMPONENT
Methane Ethane Ethylene Propylene i-Butane n-Butane C is-Trans Butane C5
Ethane/Ethylene Propane Propylene i-Butane
b) Unstabilised naphtha from ACU
Sp. Gravity at 15C Vap. Pressure - 0.710 22.0 Kg/cmg
PRODUCT CHARACTERISTICS
LPG Copper strip corrosion for 1 hr at 38C Dryness enrained water 1b Max. No free
H2S Odor (Min) Total Volatile Solution (Max.) W.T (95% Vaporised at 760 mm Hg (M
ax) Vapour pressure at 65C Kg/cmg STABILISED NAPHTHA TBP 15C HYDROCARBON % WT - Sat
urates - Olefins - Aromatics Mercaptans % wt. Cu Strip corrosion But (3hrs. at 5
0C) RVP psig (max.) FUEL GAS Methane Ethylene Ethane Propylene Propane C5 + WT. %
45.23 7.20 25.50 7.60 11.70 2.77
Absent. Level 2 0.02 + 2C 15 Max.
C5 + 140C 0.7109
64.5 23.5 12.0 0.016
2a 10.0
BATTERY LIMIT CONDITIONS
FEED / PRODUCTS Gas Unstabilised Naphtha Fuel Gas LPG Stabilised Naphtha 2.0 20.
3 5.0 50 40 40 Refinery FG system LPG Storage Naphtha/MS Tanks. Kg/cmg 2.2 16.5 0C
45 45 DESTINATION / SOURCE ACU/existing ACU
MATERIAL BALANCE
S.No. COMPONENT FEED T/YR 1. 2. 3. Gas LPG Naphtha 192696 PRODUCT T/YR. 92660 52
016 57220 Existing FG System LPG Storage Naphtha/MS Tank. DESTINATION
UTILITIES CONSUMPTION
UTILITY High Pressure Steam(SH) Medium pressure Steam Low pressure steam (SL) PR
ESSURE Kg/cmg 34 19.0 2.5 TEMP. 0C 415 211 290 CONSUMPTION 25000 Kg/hr 9594 Kg/hr
Intermittent Lost Station. ** Cooling water (WC) Inst. Air Plant Air Fresh water
2.5 3.5 6.5 7.0 40 40 Ambient 693 M/hr 60 NM/hr 340 NM/hr. * 6 *
* Intermittent. * If ACU is down consumption shall be 347M/hr CHEMICALS Caustic s
oda Corrosion inhibitor 12.0 tones/Year. 0.75 tones/Year.
C CRU(C ALYTI RE RMIN UN CATA IC EFOR NG NIT)

ytic reforming is a ch g hemical proces used to con l ss d nvert pe etroleum m C
ataly refine naphthas, typicall havin low o ery ly ng octane r ratings, into hi
, igh-octane liqu uid produ ucts called reformate which are co es h ompone ents
of high-oc ctane ga asoline (also k known a petro Bas as ol). sically, the proce
ss re t e-arrang or r ges re-stru uctures the hy ydrocar rbon mo olecules in the
naphth feed s e ha dstocks as well as bre eaking some of the molecu ules into s
malle molec o er cules. T ove The erall eff fect is t that th he uct ormate cont
ain hydrocarbons with more complex molec ns h c x cular produ refo shape havin h
ighe octan value than the hy es ng er ne es ydrocarbons in the naphtha feeds sto
ck. I so do In oing, the proce sepa e ess arates h hydroge atom from the en ms m
hydro ocarbon molecu n ules and produ d uces ver significant amounts of by ry a
yproduct hydro ogen gas for us in a n s se number of the other process invo r e
ses olved in a n moder petroleum refinery Othe bypro rn r y. er oducts are sma
amou all unts of f metha ane, eth hane, pr ropane and but tanes.
The r reaction chem n mistry All th react he tions oc ccur in t pre the esence o
a cat of talyst and a high part a tial pressure of hydrogen. Dep pending upon t
he type or ver e rsion of catalytic f reforming us as well as t des sed w the si
red re eaction severit the reactio ty, on condit tions ra ange fro tem om mperat
ures of a about 4 495 to 525 C and fro 5 om pressures of about 5 to 45 atm. f 5 T
he c commonly used catalyt refo tic orming catalys contain nob met sts ble tals
suc ch as pla atinum a and/or rhenium which are ve sus m, h ery sceptible to po
oisoning by g sulfur and nitrogen compou r unds. Therefore, the naphth feed T ha
dstock t a to cataly ytic ref former is alway pre-process in a hydrodesulfu ys
sed urizatio unit on which removes both the su h h ulfur an the n nd nitrogen co
mpo n ounds. The f four maj cata jor alytic r reforming reac ctions a are:1: The
dehyd e drogena ation of napht f thenes to conv vert the into aromat em tics as
exemp plified in the convers c sion met thylcyc clohexan (a na ne aphthen to t
ne) toluene: :-
2: The isome e erizatio of no on ormal paraffin to is p ns soparaf ffins as exem

p s plified in i the co onversion of normal o octane to 2,5-D t Dimethy ylhexan
(an is ne soparaf ffin), as s shown below: n
3: The dehyd e drogena ation and arom matizat tion of paraff fins to a aromatics
(comm monly ca alled de ehydroc cyclizat tion) as exemp plified in the co n onv
ersion of norma hepta to toluene, as sho al ane t own belo ow:
4: The hydro e ocrackin of p ng paraffin into smaller molecules as exemplified b
y ns r b the cr racking of normal hep ptane in isop nto pentane and et e thane,
a shown below as w:
The h hydrocr racking of para affins is the on one of the above f s nly four ma
ajor reforming re eactions that c s consume hydr es rogen. T isom The merizat ti
on of normal paraffins does not consum or pr c me roduce h hydroge How en. wever
, b both the dehyd drogena ation of naphth f henes and the dehydr a rocycliz zat
ion o paraf of ffins produ hydr uce rogen. The ove T erall ne produ et uction o
hydro of ogen in the catalytic reforming of petrol f leum na aphthas ranges from
a s s about 50 to 20 cubi mete 5 00 ic ers of hyd drogen gas (at 0 C and 1 atm p
er cubic m t m) meter of liquid naphth f ha feeds stock.
Typical naph htha fe eedstoc cks overhea liquid distilla from atmo ad d ate osph
eric distill c lation c column i called is d The o napht and will bec tha come a
major compon nent of the ref finery's gasoli s ine (petro prod ol) duct aft it
is furthe proc ter s er cessed t through a cata h alytic hydro odesulfu urizer t
o remo sulf t ove fur-cont taining hydroc carbons and a c catalytic reformer to
reform its hy m ydrocarb molecules into mo com bon ore mplex m molecule es with
a higher octane rating value. The na r g . aphtha is a mix xture o very many of
differ rent hy ydrocarbon com mpounds. It ha an initial boiling po as oint of a
about 35 C and a fina boiling point of about 200 C, and it cont d al g d tains pa
araffin,
naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from those contai
ning 4 carbon atoms to those containing about 10 or 11 carbon atoms. "light" nap
htha containing most (but not all) of the hydrocarbons with 6 or less carbon ato
ms and a "heavy" naphtha containing most (but not all) of the hydrocarbons with
more than 6 carbon atoms. The heavy naphtha has an initial boiling point of abou
t 140 to 150 C and a final boiling point of about 190 to 205 C. The naphthas deriv
ed from the distillation of crude oils are referred to as "straight-run" naphtha
s. It is the straight-run heavy naphtha that is usually processed in a catalytic
reformer because the light naphtha has molecules with 6 or less carbon atoms wh
ich, when reformed, tend to crack into butane and lower molecular weight hydroca
rbons which are not useful as high-octane gasoline blending components. Also, th
e molecules with 6 carbon atoms tend to form aromatics which is undesirable beca
use governmental environmental regulations in a number of countries limit the am
ount of aromatics (most particularly benzene) that gasoline may contain.
Key specifications of Petrol : BS-II BS-III/ Euro-III equivalent Regular Sulphur
, (max) Benzene, (max) RON (min) Aromatics, (max) Vol % ppm Vol w % 500 3 88 No
Spec. No Spec. 150 1 91 42 21 Premium 150 1 95 42 18 Euro-IV Regular 50 1 91 35
21 Premium 50 1 95 35 18
Olifins, Vol % (max)
TEMP PERAT TURE & PRES SSURE COND DITIO N : SL EQUIPMENT E (KG/C 2G) CM NO. 1. 2
. 3. 4. 5. 6. 7. FEED B F BEFORE E 02-EE-0 0 001 FURNA F ACE I/L L REACTO I/L R
OR L REACTO O/L R OR L TEM MPERAT TURE (0C) EO OR SOR S EOR PRESSURE SOR R
6 65.0 (T TI-1112) )65.0 28 85.3 (T TI-1114) )325.0 33 30.0 (T TI-1122) )370.0 3
3 30.0 37 70.0
20.9 9 17.6
20.9 9 17.6 6
16.5 (PI-110 16.5 5 02) 5 15.0 (PI-110 15.0 0 03) 0 13.0 0 13.0 0
HYDRO H O-TREA ATER SEPARA S ATOR 4 45.0 (T TI-1203)45.0 HYDRO H O-TREA ATER PUR
GE STRIPP S PER FEE ED AFTER EXCHA A ANGER186.0 (TI-1311 1)186.0 0 14.5 1 STRIPP
S PER OV VER-HEA AD136.0 127.0 1 14.4 (PI I-1303) )14.4
14.5 5
(P PI-1302 2) (T TI-1312 2) ----8. 9. 10.
STRIPP S PER BOTTOM2 225.0 (TI-1316 6)225.0 ----0 -REFLUX R X 5 58.5 (T TI-1313)
)57.3
18.2 (PI-1304 18.2 2 & PI-13 305)
BRIEF PROCESS DESCRIPTION: (I)NAPHTHA SPLITTER UNIT (NSU) :

IBP-140 0C cut napht
ha from storage (TK 250, 251, 252) is fed to splitter column 01-CC-001 under flo
w control by off site pump 41-PA-1A/B at tray No. 14. The feed is heated up to 9
5 0C in splitter feed/bottom exchanger 01-EE-001 A/B against splitter bottom str
eam before it enters the column. The over head vapours are totally condensed in
air condensers 01-EA-001. The liquid collected is pumped by splitter reflux pump
01-PA-001 A/B and one part sent as top reflux back to the column under flow con
trol 02-FC1102 to maintain the top temperature. The balance, which constitutes t
he IBP-70 0C cut naphtha is sent to storage under reflux drum level control 01-L
C-1101 after cooling in a water cooler 01-EE-002. Reflux drum boot water is drai
ned in OWS manually. The pressure of splitter is controlled at reflux drum by pa
ssing a part of hot column overhead vapours around the condenser or releasing th
e reflux vapours to flare through a split range controller (01-PC-1101).
The spl
itter bottom product which constitutes 70-140 0C cut naphtha is pumped to splite
r feed/bottom exchanger 01-EE-001 A/B by hydro treater feed pumps 01-PA-003 A/B.
The bottom product after exchanging heat with feed is split into two streams. O
ne is fed to the hydro treater unit at a temp. of 65 0C and the other is sent to
storage under column level control 01-LC-1102 after being colled in splitter bo
ttom column 01-EE-003. The heat necessary for splitter reboiling is supplied by
splitter reboiler furnace 01-FF-001 and desired temperature maintained by contro
lling the fuel firing. The circulation through reboiler is provided by splitter
reboiler pumps 01-PA-002 A/B. 01-FF-001 is double pass vertical
cylinderical furnace having four burners fired from the bottom. It has soot blow
ing facility for convection section.
(II)HYDROTREATER UNIT (HTU) : REACTION AND SEPARATION SECTION :
The naphtha from
NSU is fed to HTU by a pump 01-PA-003 A/B. The feed flow is controlled by flow
control valve 02-FC-1101. The feed then mixed with Rich Hydrogen Gas from HP sep
arator of reformer. The Rich Hydrogen gas flow is controlled by 02-FC-1202. Both
the liquid naphtha and rich hydrogen gas are pre-heated in a series of exchange
rs 02-EE001 A/B/C/D/E/F which are feed/reactor effluent heat exchangers. Then mi
xture is heated upto reaction temperature in a furnace 02-FF-001 and fed to the
reactor 02-RB-001. The furnace 02-FF-001 is four pass having three burners fired
from bottom. The furnace is having facility of soot blowing. The reactor inlet
temperature is maintained by 02-TC-1101 cascaded with either fuel oil or fuel ga
s PC's. The furnace is provided with all safety shut down inter locks. It has al
so provision of decoking. The desulfurisation and hydro treating reaction takes
place in 02-RB-001 at almost constant temperature since heat of reaction is quit
e negligible. The reactor is provided with facility of steam and air for regener
ation of catalyst. The catalyst for reactor is HR-306. The reactor catalyst bed
has been provided with five number of thermo couple points at various location t
o get the bed temperature during regeneration of the catalyst.
The reactor efflu
ent after having heat exchanged in 02-EE-001 series with feed goes to air cooler
02-EA-001. The air cooler fans pitch is variable i.e. cooling load can be adjus
ted as per situation requirement. After air cooler the effluent is cooled in a t
rim cooler 02-EE-002. The product is collected in a separator vessel 02-VV-001.
Sour water is
drained from the separator drum boot manually. The separator drum pressure is ma
intained by 02-PC-1201, releasing the excess gas in FG system. In event of emerg
ency the separator excess pressure can be released to flare through an on-off c/
v HV-1201.
A line has been provided to feed the naphtha to stripper, during star
t up, bypassing the reaction/separation section. STRIPPER SECTION :
The separato
r liquid is pumped by 02-PA-001A/B under flow control 02FC-1201 cascaded with 02
-LC-1201 to stripper feed/bottom exchanger 02-EE-003 A/B/C when it gets heat exc
hanged by hot stripper bottom stream. The stripper column consists of 28 Nos. of
valve trays one to eight number of trays are single pass and the rest double pa
ss. Feed coming from 02-EE-003 A/B/C enters at 9th tray from two sides. The over
head vapours are cooled down in 02-EA-002 air condenser and collected in 02VV-0
02 stripper refflux drum. The fan load can be adjusted. The condensed hydro-carb
ons are returned to column top by pump 02-PA002A/B under flow control 02-FC-1301
cascaded with 02-LC-1302 as reflux to maintain the top temp. The water accumula
ted in the boot is sent for disposal as sour water. The reflux drum pressure is
maintained by 02-PC-1301 releasing excess gas in the FG system. The facility is
there to inject corrosion inhibitor by pump 02-PA-005A.
Stripper bottom product
exchanged heat with stripper feed in 02-EE003A/B/C and then sent to reformer as
hot feed. The excess or required hydro-treated naphtha is sent to storage after
being cooled in 02-EE-004 A/B under level control 02-LC-1301.
The necessary heat
for stripper reboiling is supplied by 02-FF-002 reboiler heater. 02-CC-001 prod
uct is circulated through 02-FF-002 single pass cylinders vertical furnace by 02
-PA-003 A/B. Partial
vap pourizat tion occ curs in 02-FF-002. R Reboilin is controlled by 02 ng d 2-T

C-13 301 at 3rd pla from the bottom of 02ate m -CC-001. Furnace is p provide wit
h all ed saf fety int lock ter ks.
Hydro tre eated naphtha from hydro treate unit is pum n a er mped to requir o re
d pre essure b by 03-P PA-001 A/B un nder flo cont ow trol 03-FC-1101 A/B and a
mix xed wit recy th ycle gas from the recycle gas co s m ompress sor (03 3-KA-00
01). The mixed feed is pre heated in the feed-e d d effluent excha anger 0 03-E
E-0 001 followed by fee ed/efflu uent ex xchange 03-E er EE-002 Then the m 2. n
mixture is e bro ought u upto the react tion tem mperature (48 0C) by hea 80 ati
ng in the pren hea ater 03 3-FF-00 and t 01 then fed to 1st reactor 03-R t RB-00
1. .
As the re eaction is end n do-ther rmic, th tem he mperature drops, so the
first rea actor ef ffluent is heat in the firs inter heater 03-FF t ted t st r F
-002 p prior to be sen to th secon reac nt he nd ctor 03-RB-00 02.
In the sam wa
y 03-RBme -002 ef ffluent is heat in the seco inte heater ted ond er 03-FF-003 p
rior to be f to the thir reac fed t rd ctor 03-RB-003. The efflu uent fro the la
st re om eactor 03-RB-003 is split into two strea o ams and send for hea recover
y pa d at arallely to feed/efflu uent ex xchange (03-E er EE002) and stablizer r
e d eboiler (03-EE-003) The outlet from the two ). t exc changer is co rs ombine
d by a these wa valve 03-TI d ay e IC-1101 and th cooled 1 hen dow suc wn ccesiv
el in t ly the Ze eemann Secat then ex xchanger (03 3-EE-00 01),
reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004. The coole
d reactor effluent is flashed in the reformer separator 03-VV001.
Vapour and liq
uid phase are separated in separator 03-VV-001. Part of the gas phase constitute
s the hydrogen recycle gas to the reactor circulated by recycle gas compressor 0
3-KA-001. Remaining amount, corresponding to the amount of gas produced, is comp
ressed by the hydrogen rich gas compressor 03-KA-002 A/B. The pressure control i
n separator is achieved by a kick back gas flow from HP Absorber (03-VV003) to s
eparator. Should the gas be produced in excess to 03-KA-002 A/B capacity, degass
ing in split range to fuel gas is performed, through 03-PC-1401 A and 03-PC-1402
. The separator liquid is sent by reformer separator bottom pumps (03-PA002 A/B)
under level control 03-LC-1401 for recontacting with the gas compressed by 03-K
A-002 A/B.
The hot flue gases from all the three reformer furnaces are combined
and sent to stream generation system forwaste heat recovery to produce MP steam.
Provision is there to dry the recycle gas into a dryer (03-RB004). The dryer ca
n later be regenerated.
The unit has also been provided with facilities for cont
inuous chloriding, water injection, DMDS/Ccl4 injection and caustic soda circula
tion. The separator (03-VV-001) vapour after passing through KO drum (03VV-002)
is compressed in the H2 Rich Gas Compressor (03-KA-002 A/B) and recontacted with
separator liquid. The recontacted vapour and liquid is cooled in a cooler (03-E
E-005) and then fed to HP absorber (03-VV003). The aim of this device is to allo
w for high recovery of the C5 contained in the gas phase of separator and improv
e the quality (H2 concentration) of the produced gas.
A part of hydrogen rich vapour goes to HTU as a make up hydrogen and balance goe
s to the fuel gas system under pressure control 03-PC-1601.
The liquid from the
03-VV-003 is drawn off under level control 03-LC1601 and mixed with stabilizer v
apour distillate. The combined stream is cooled in LPG absorber feed cooler 03-E
E-006 and flashed in LPG absorber. Off-gas is sent under pressure control to fue
l gas system. The liquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA
-003 A/B. After pre heating in stabilizer feed/bottom exchanger 03-EE-007 the mi
xture is fed to the stabilizer 03-CC-001 at tray No. 13. Stabilizer over head va
pours are partialy condensed in stablizer condenser 03-EE-008 and flashed in sta
bilizer reflux drum 03-VV-005. The vapour phase is sent to LPG absorber for C3 a
nd C4 recovery. A part of condensed liquid is pumped as reflux to the column by
stabilizer reflux pump 03-PA-004 A/B under the flow control and the balance is s
ent to LPG Recovery Unit under level control of reflux drum.
The heat of reboili
ng to the stabilizer is provided by the hot reactor effluent in the stabilizer r
eboiler 03-EE-003 and the desired
temperature maintained by controlling the flow of reactor effluent by the three
way valve. The bottom product, stabilized reformate, is cooled in the feed/botto
m exchanger 03-EE-007followed by reformate cooler 03-EA-002 and reformate trim c
ooler 03-EE-009 before being routed to storage Tk 77 to 84.
FLUIDISED CATALYTIC CRACKING

Fluid catalytic cracking (FCC) is the most important conversion process used in
petroleum refineries. It is widely used to convert the high-boiling, high-molecu
lar weight hydrocarbon fractions of petroleum crude oils to more valuable gasoli
ne, olefinic gases and other products. Cracking of petroleum hydrocarbons was or
iginally done by thermal cracking which has been almost completely replaced by c
atalytic cracking because it produces more gasoline with a higher octane rating.
It also produces byproduct gases that are more olefinic, and hence more valuabl
e, than those produced by thermal cracking.
The feedstock to an FCC is usually that portion of the crude oil that has an ini
tial boiling point of 340 C or higher at atmospheric pressure and an average mole
cular weight ranging from about 200 to 600 or higher. This portion of crude oil
is often referred to as heavy gas oil. The FCC process vaporizes and breaks the
long-chain molecules of the high-boiling hydrocarbon liquids into much shorter m
olecules by contacting the feedstock, at high temperature and moderate pressure,
with a fluidized powdered catalyst.
In effect, refineries use fluid catalytic cracking to correct the imbalance betw
een the market demand for gasoline and the excess of heavy, high boiling range p
roducts resulting from the distillation of crude oil.
The first commercial use of catalytic cracking occurred in 1915 when Almer M. Mc
Afee of the Gulf Refining Company developed a batch process using aluminum chlor
ide (a Friedel Crafts catalyst known since 1877) to catalytically crack heavy pe
troleum oils. However, the prohibitive cost of the catalyst prevented the widesp
read use of McAfee's process at that time.
The mode FCC units a all continuo processes which o ern are c ous operate 24 e h
ou a da for as much as 2 to 3 yea betw urs ay a h ars ween sh hutdown for r ns r
outine ma aintenan nce.
There are a numb of differe prop e ber ent prietary desi
gns that have b y t been dev veloped for mo d odern F FCC unit Each design is av
a ts. h n ailable u under a license e tha must be pur at t rchased from the des
d t sign dev veloper by any petrole eum ref fining company desiring to co y onst
ruc and o ct operate an FCC of a g e C given des sign. Bas sically, there are tw
o differ a o rent con nfigurat tions fo an FC unit: the or CC "st tacked" type w
here th reac w he ctor and the ca d atalyst regene erator a are con ntained in a
sin ngle ves ssel wit the r th reactor above the cat talyst reg generat and the
"si tor ide-by-s side" ty whe the reacto and c ype ere e or catalyst t reg gene
rat are in two separat vessels. The are the ma tor te ese e ajor FC CC des signe
rs and lic censors:
Sid de-by-s side con nfigurat tion:
CB&I Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions In
ternational Stone & Webster Engineering Corporation (SWECO) / Institut Francais
Petrole (IFP)
Universal Oil Products (UOP) - currently fully owned subsidiary of
Honeywell
Reactor and Regenerator
The schematic flow diagram of a typical moder
n FCC unit in Figure 1 below is based upon the "side-by-side" configuration. The
preheated high-boiling petroleum feedstock (at about 315 to 430 C) consisting of
long-chain hydrocarbon molecules is combined with recycle slurry oil from the b
ottom of the distillation column and injected into the catalyst riser where it i
s vaporized and cracked into smaller molecules of vapor by contact and mixing wi
th the very hot powdered catalyst from the regenerator. All of the cracking reac
tions take place in the catalyst riser. The hydrocarbon vapors "fluidize" the po
wdered catalyst and the mixture of hydrocarbon vapors and catalyst flows upward
to enter the reactor at a temperature of about 535 C and a pressure of about 1.72
barg. The reactor is in fact merely a vessel in which the cracked product vapor
s are: (a) separated from the so-called spent catalyst by flowing through a set
of two-stage cyclones within the reactor and (b) the spent catalyst flows downwa
rd through a steam stripping section to remove any hydrocarbon vapors before the
spent catalyst returns to the catalyst regenerator. The flow of spent catalyst
to the regenerator is regulated by a slide valve in the spent catalyst line.
Sin
ce the cracking reactions produce some carbonaceous material (referred to as cok
e) that deposits on the catalyst and very quickly reduces the catalyst reactivit
y, the catalyst is regenerated by burning off the deposited coke with air blown
into the regenerator. The regenerator operates at a temperature of about 715 C an
d a pressure of about 2.41 barg. The combustion of the coke is exothermic and it
produces a large amount of heat that is partially absorbed by the regenerated c
atalyst and provides the heat required for the vaporization of the feedstock and
the endothermic cracking reactions that take place in the catalyst riser. For t
hat reason, FCC units are often referred to as being heat balanced.
The hot cata
lyst (at about 715 C) leaving the regenerator flows into a catalyst withdrawal we
ll where any entrained combustion flue gases are allowed to escape and flow back
into the upper part to the regenerator. The flow of regenerated catalyst to the
feedstock injection point below the catalyst riser is regulated by a slide valv
e in the regenerated catalyst
line. The hot flue gas exits the regenerator after passing through multiple sets
of two-stage cylones that remove entrained catalyst from the flue gas,
The amou
nt of catalyst circulating between the regenerator and the reactor amounts to ab
out 5 kg per kg of feedstock which is equivalent to about 4.66 kg per litre of f
eedstock. Thus, an FCC unit processing 75,000 barrels/day (12,000,000 litres/day
) will circulate about 55,900 metric tons per day of catalyst. Distillation colu
mn The reaction product vapors (at 535 C and a pressure of 1.72 barg) flow from t
he top of the reactor to the bottom section of the distillation column (commonly
referred to as the main fractionator) where they are distilled into the FCC end
products of cracked naphtha, fuel oil and offgas. After further processing for
removal of sulfur compounds, the cracked naphtha becomes a high-octane component
of the refinery's blended gasolines.
The main fractionator offgas is sent to wh
at is called a gas recovery unit where it is separated into butanes and butylene
s, propane and propylene, and lower molecular weight gases (hydrogen, methane, e
thylene and ethane). Some FCC gas recovery units may also separate out some of t
he ethane and ethylene. Although the schematic flow diagram above depicts the ma
in fractionator as having only one sidecut stripper and one fuel oil product, ma
ny FCC main fractionators have two sidecut strippers and produce a light fuel oi
l and a heavy fuel oil. Likewise, many FCC main fractionators produce a light cr
acked naphtha and a heavy cracked naphtha. The terminology light and heavy in th
is context refers to the product boiling ranges, with light products having a lo
wer boiling range than heavy products. The bottom product oil from the main frac
tionator contains residual catalyst particles which were not completely removed
by the cyclones in the top of the reactor. For that reason, the bottom product o
il is referred to as a slurry oil. Part of that slurry oil is recycled back into
the main fractionator above the entry point of the hot reaction product vapors
so as to cool and partially condense the reaction product vapors as they enter t
he main fractionator. The remainder of the slurry oil is pumped through a slurry
settler. The bottom oil from the slurry settler contains most of the slurry oil
catalyst particles and is recycled back into the catalyst riser by combining it
with the FCC feedstock oil. The socalled clarified slurry oil or decant oil is
withdrawn from the top of slurry settler for use elsewhere in the refinery or as
a heavy fuel oil blending component.
Regenerator flue gas

Depending on the choice of FCC design, the combustion in th
e regenerator of the coke on the spent catalyst may or may not be complete combu
stion to carbon dioxide (CO2). The combustion air flow is controlled so as to pr
ovide the desired ratio of carbon monoxide (CO) to carbon dioxide for each speci
fic FCC design.[1][4]
In the design shown in Figure 1, the coke has only been pa
rtially combusted to CO2. The combustion flue gas (containing CO and CO2) at 715
C and at a pressure of 2.41 barg is routed through a secondary catalyst separato
r containing swirl tubes designed to remove 70 to 90 percent of the particulates
in the flue gas leaving the regenerator.[8] This is required to prevent erosion
damage to the blades in the turboexpander that the flue gas is next routed thro
ugh. The expansion of flue gas through a turbo-expander provides sufficient powe
r to drive the regenerator's combustion air compressor. The electrical motor-gen
erator can consume or produce electrical power. If the expansion of the flue gas
does not provide enough power to drive the air compressor, the electric motor/g
enerator provides the needed additional power. If the flue gas expansion provide
s more power than needed to drive the air compressor, than the electric motor/ge
nerator converts the excess power into electric power and exports it to the refi
nery's electrical system.[3]
The expanded flue gas is then routed through a stea
m-generating boiler (referred to as a CO boiler) where the carbon monoxide in th
e flue gas is burned as fuel to provide steam for use in the refinery as well as
to comply with any applicable environmental regulatory limits on carbon monoxid
e emissions.[3]
The flue gas is finally processed through an electrostatic preci
pitator (ESP) to remove residual particulate matter to comply with any applicabl
e environmental regulations regarding particulate emissions. The ESP removes par
ticulates in the size range of 2 to 20 microns from the flue gas.[3] The steam t
urbine in the flue gas processing system (shown in the above diagram) is used to
drive the regenerator's combustion air compressor during start-ups of the FCC u
nit until there is sufficient combustion flue gas to take over that task.
COKER A
GENERAL DATA 1. Capacity 2. On-stream hours per year. 3. Original Technology 4.
Year of Commissioning 5. Turn Down 0.6 MMTPA 7200 Russian 1964 95 %
The unit is designed for the following three cases:CASE-I Feed corresponding to
future refinery configuration having Resid Desulphurisation unit, while processi
ng 6.0 MMTPA high sulphur crude 50:50 wt Arab mix) CASE-II Feed corresponding to
future refinery configuration without Resid Desulphurisation, while processing
6.0 MMTPA low sulphur crude (Bonny light). CASE-III Feed corresponding to future
refinery configuration without Resid Desulphurisation, while processing 4.2 MMT
PA low sulphur crude (Bonny light).
PROCESS DESCRIPTION Delayed coking process is an effective conversion process for
upgradation of the heavy residuals from the refinery distillation unit into val
uable distillates and premium quality petroleum coke. In this process the heavy
residual feed stocks are heated up to coking temperature and the mixture is allo
wed to stand for prolong period in large insulated vessels called coke drums. Du
ring this time, the heavy stock undergoes thermal cracking at large high b.pt. H
/C molecules are decomposed into smaller lower boiling point molecules and at th
e same time some reactive molecules undergoes pyrolytic polymerization forming f
uel oil
and coke. Coke is formed by two different mechanism. In one the colloidal suspen
sion of the asphltene and resin components is re-arranged resulting in the preci
pitation of the compounds to form highly-cross-linked structure of amorphous cok
e. The compounds are also subjected to a cleavage of this sulphatic groups. Coke
formed from these resinasphatene compounds is undesirable for making premium gr
ade coke. The other reaction mechanism involves the polymerisation and condensat
ion of aromatics, grouping a large number of these compounds to such a degree th
at eventually coke is formed. The coke produced from these aeromatic compounds i
s the most suitable premium grade needle coke. The other products of pyrolysis a
re separated into distillate fuels and recovered separately in a fractionator co
lumn. Reduced crude is received in the Feed Surge Drum in Coker-A through offsit
e Pumps. The feed RCO is then preheated to 240C by heat exchanger against Coker p
roducts like Coker Kero, Light Diesel Oil (LDO) Product and LDO CR. The preheate
d RCO is fed to fractionator column at two levels, one below and the other above
the vapour inlet nozzle. This facility is provided to control fractionator bott
om temperature. The feed material along with the recycle stock is pumped to the
reaction coils of the coker furnace at a temperature of 340 360 C and the materia
l is heated to the temperature of 500C which resulted in partial vapourization an
d mild cracking of the stock. The vapour liquid mixture then enters the coke cha
mber which is in coking service, where the vapour experience further cracking as
it passes through the coke chamber and the liquid experience successive crackin
g and polymerization until it is converted to vapour and coke. The unit has two
blocks and each block has two coke
chambers, one in coking service while the other is being decoked with high press
ure water jets. Each block has got individual heater. The coke chamber overhead
vapours enter the fractionator via a quench column at a temperature of about 425C
. In the fractionator column, gas and naphtha are obtained as overhead products
and kerosene, LDO and CFO as side draw off products. Kerosene, LDO and CFO are s
team stripped in the stripper columns, cooled prior to their being routed to the
ir destinations. A LDO circulating reflux stream is drawn and is utilised for HP
steam generation. LDO Product, CFO Product and FO IR are utilized for generatin
g MP steam. A cold LDO stream is used as quench in the quench column. Besides re
finery slop and gas oil from offsites tank can be used as quench in the vapour l
ine of the coke chambers. The residue from the bottom of quench column is sent t
o storage after further cooling. The vapour from the fractionator overhead are c
ooled in air cooler and water condensers and then led to reflux drum where gas a
nd liquid separate out. The gases from the fractionator reflux drum sent to LPG
Recovery unit of the refinery. Condensed naphtha from reflux drum is also routed
to the LPG recovering unit for stablilization. A part of condensed naphtha sent
back to fractionator column as top reflux. Coke from the cooled drained chamber
is cut and cleared by hydraulic jets operating at a pressure of about 200 Kg/cm.
Coke along with water falls to the ground. The coke from the drop-out area is s
ent to storage using Coke Sizer and conveyors.
COKER B
PROCESS DESCRIPTION
Delayed
coking
process
is
an
effective
conversion
process
for
upgradation of the heavy residuals from the refinery distillation unit into valu
able distillates and premium quality petroleum coke.
In this process the heavy r
esidual feed stocks are heated up to coking temperature and the mixture is allow
ed to stand for prolong period in large insulated vessels called coke drums. Dur
ing this time, the heavy stock undergoes thermal cracking at large high b.pt. H/
C molecules are decomposed into smaller lower boiling point molecules and at the
same time some reactive molecules undergoes pyrolytic polymerization forming fu
el oil and coke. Coke is formed by two different mechanism. In one the colloidal
suspension of the asphltene and resin components is re-arranged resulting in th
e precipitation of the compounds to form highly-crosslinked structure of amorpho
us coke. The compounds are also subjected to a cleavage of this sulphatic groups
. Coke formed from these
resinasphatene compounds is undesirable for making premium grade coke.
reaction mechanism involves the polymerisation and
The other
condensation of aromatics, grouping a large number of these compounds to such a

degree that eventually coke is formed. The coke produced from these aeromatic co
mpounds is the most suitable premium grade needle coke. The other products of py
rolysis are separated into distillate fuels and recovered separately in a fracti
onator column.
Reduced crude is received in Coker-B from offsite storage tanks by a 18 dia pipel
ine. The feed stock RCO from storage is preheated to 200C by
heat exchanger against Coker products like Coker Kero, heavy gas oil (HGO), coke
r fuel oil (CFO) and residue.
The preheated RCO is further heated to 240C in the
pre-heat section of the coker furnace and fed to fractionator column. This feed
goes to the fractionator is at two levels, one below and the other above the vap
our inlet nozzle. This facility is provided to control fractionator bottom tempe
rature. The feed material along with the recycle stock is pumped to the reaction
coils of the coker furnace at a temperature of 380C. The material is heated to a
temperature of 500C which resulted in partial vapourization and mild cracking of
the stock. The vapour liquid mixture then enters the coke chamber which is in c
oking service, where the vapour experience further cracking as it passes through
the coke chamber and the liquid experience successive cracking and polymerizati
on until it is converted to vapour and coke. The unit has two coke chambers, one
in coking service while the other is being decoked with high pressure water jet
s. The coke chamber overhead vapours enter the fractionator via a quench column
at a temperature of about 425C. In the fractionator column, gas and naphtha are o
btained as overhead products and kerosene, HGO and CFO as side draw off products
. Kerosene, and HGO are steam stripped in the stripper columns, cooled prior to
their being routed to their destinations.
HYDROGEN GENERATION UNIT

GENERAL DATA Design Capacity Stream Factor Turn down ratio Original Technology D
ate of Commissioning 34 TMT H2 production 8,000 hours per year 30 % Haldor Topso
e 24 TH Apri2002
BRIEF PROCESS DESCRIPTION To meet the make up requirement of Hydrogen for DHDT U
nit, naphtha steam reforming type Hydrogen unit has been considered where Hydrog
en is produced by steam reforming of Naphtha. Naphtha is
first desulphurised over a desulphurisation catalyst where, in presence of hydro

gen, non-reactive sulphur compounds are hydrogenated to hydrogen sulphide which
is then absorbed on Zince Oxide beds. The desulphurised feed is mixed with prehe
ated steam and then heated to the desired temperature before entering steam refo
rming furnace tubes containing a nickel based catalyst. The reformed gases leave
the tubes and after exchanging heat to generate steam, pass through a CO shift
convertor where most of the carbon monoxide is reacted with excess steam to prod
uce additional hydrogen and carbon dioxide. The converted gases leave the reacto
r and preheat the incoming Naphtha, Boiler Feed water and Demineralised water. T
he impurities like carbon monoxide, carbon dioxide, methane, nitrogen and water
vapour are removed by high pressure adsorption on molecular sieves. Activated ca
rbon and alumina gel in PSA (Pressure Swing Adsorption) system. All adsorbed gas
es are removed during deadsorption & regeneration of the beds and used as fuel i
n reformer furnace, and Hydrogen with 99.5% (vol) purity is fed to bullet / DHDT
unit.
Feed Stock DESIGN
CASE 1: 30% (WT%) MIXTURE OF RFCCU OFF GAS AND 70% (WT%) SRN CASE 2: 100% CAPACI
TY ON SRN Type of Feed Feed composition GAS / LIQUID For Liq. Feed (SRN C5-90OC C
UT) For gas feed (RFFCU OFF GASES)
ATACHED AS ANNEXURE-1
Gas MW
Feed Characteristics
For Liq. Feed
For gas feed
(SRN C5-90OC CUT)

(RFFCU OFF GASES)
Liq. Sp. Gravity @ 150C Feed composition /TBP
0.692 ATACHED AS ANNEXURE-1 ATACHED AS ANNEXURE-1
Cut range, deg.C Total Sulfur / Nitrogen, WT% PONA, Vol%
C5-90OC 0.025 / NIL ATACHED AS ANNEXURE-1
Distillation ASTM D86, OC
IBP 10 VOL% 50 VOL% 70 VOL% FBP
: 41 : 44 : 59 : 71 : 98
Calorific Value, Kcal/Kg C/H Ratio, wt / wt Any other additional feed to PSA uni
t Feed Type Flow rate (Kg/hr) Fuel Type Liquid Naphtha Purge gas from PSA Syn. G
as (in case PSA shut down)
10,492 5.7
Flow rate (Kg/hr) Internal fuel to Furnace (off Gas from PSA), NM /Hr
3
CASE-1 CASE-2
PSA I OFF GAS : 25845
25250
Steam/carbon ratio for the feed for Steam Reforming Blow down 2nd Demister vent
quantities Kg/hr Inlet temperature to the tabular Reformer, deg, C Reformer exit
temperature Deg, C
640
930
Pressure around the reformer
inlet of reformer, Kg/cm2 a / out let of reformer, Kg/cm2 a Efficiency of PSA, %
Whether pre-reformer is used (Yes/No) Operating condition for pre-reformer Pres
sure, Kg/cm2 a (Inlet/ Outlet) / Temperature, deg.C (Inlet/ Outlet) Pre-reformer
location (After/before feed preheat coil) No. of Stages of Reforming Feed tempe
rature/pressure @ unit b/l (deg.C/ Kg/cm2 a) 40 / 5.0 Product temperature/pressu
re @ unit b/l (deg.C/ Kg/cm2 a) Product Quality (Percent purity of Hydrogen) 99.
9 45 (MAX.) / 21 (MIN.) SINGLE SRN (C5 90) RICH GASES FROM RFCCU 51 / 13.5 BEFORE
FEED PREHEAT COIL YES 28.4 27.9 / 490 -419 24.2
Product yield, (NM3/hr) Extent of Air cooling, deg.C Product run down temperatur
e cooler inlet, deg.C DM water heater heating (by syngas) if any Temperature of
syn gas to the Exchanger, deg.C
47252 20 131
270 / 331 / 224
Heat recovered, (MM Kcal/hr)

2.29 / 4.22 / 3.30
Flue gas heat recovery
Air pre-Heaters for the furnace Type of air PreHeater (MM Kcal/hr) Steam generat
ion duty in furnace (MM Kcal/hr) 9.04 9.15 + 4.85
Steam superheating duty in furnace (MM Kcal/hr)
7.84
Feed super heating duty in furnace (MMKcal/hr)
4.26 + 4.12
Final flue gas temperature, deg.C Cooling Water Type (Once thru/circulating Sea/
Water) Flow Rate (m3/hr) Supply / return temperature (oC) Flow rate, (T/hr)
159 Design Data Circulating Water 120 33 / 42 Generation Consumption in the unit
Net import / export
HP Steam MP Steam LP Steam Others, if any Operating Pressure & Temperature (Kg/c
m2a)/ oC) HP Steam MP Steam LP Steam Total Power Consumption in HGU (KW)
68.6 36.0 2.0 - 32.6 + 2.0 36.0 / 400 11 / 275 4.5 / 180 2000
DIESEL HYDRO EATI D H OTRE ING UNIT ( D T DHDT ) T

GEN NERAL DATA L A
Design Capacity : D 2.2 MMTPA M Stream Factor : S m 8,000 hours per ye 0 s ear :
40% of de Turndo wn T % esign ca apacity y Original Techn O nology : UOP USA P,
T Date of Commissionin : 20TH Oct2 D f ng 2002
EDSTO OCK DE EFINIT TION FEE
e ntaining Strai g ight run Gasoil from low The design feed is a blend con sulph
ur im mported crude (SRGO-LS), Straig run Gasoil from h e ght high mported crude
from middle east ( e e (SRGO-HS), T Total Cy ycle Oil sulphur im om CU O), ht e
r oil m r LCGO) with fro FCC (TCO Ligh Coke Gaso from Coker unit (L bel low ment
ioned prope d erties. (Table II-1)
Case I Capacity MTPA (BPSD) 2.2 (47460)

Case II 2.2 (47855)
Case III 2.2 (47433)
SRGO-LS SRGO-HS Composition Wt % TCO-FCC LCGO Case-1 API Sulphur Wt % Nitrogen w
ppm Bromine Number g/100g Flash Point Pour Point Metal Ni+V wppm Iron wppm Cetan
e Number Silicon wppm Chloride wppm 30.26 0.726 664
46.0 4.6 31.6 17.8
SRGO-LS SRGO-HS TCO-FCC LCGO Case-2 31.62 1.92 610
6.0 48.0 31.0 15.0
SRGO-LS SRGO-HS TCO-FCC LCGO Case-3 30.18 1.37 758
26.0 12.7 39.2 22.1
17
16
21
50 3 0.86 0.3 42.4 0.53 5.1 Case I
50 3 0.91 0.3 43.7 0.45 4.8 Case II
58 3 1.07 0.3 39.0 0.66 6.2 Case III
ASTM Distillate IBP 10 % 30 % 141 192 263 142 192 259 139 182 248
50 % 70 % 90 % 95 % FBP
288 309 344 359 399
284 309 348 361 402
280 305 343 358 399
MAKE UP HYDROGEN The make-up hydrogen for the Hydrotreater will be supplied from
the Hydrogen Unit having the following characteristics:99.5 Vol. % min Hydrogen
Purity Chloride 1 vppm max Balance will comprise mainly methane & trace of CO,
CO2 and N2. PRODUCT SPECIFICATION The Hydrotreated products shall be routed to t
he storage and the properties of the Diesel will meet the following specificatio
n.
Properties Flash Point Cetane Number Sulphur Wt ppm Pour Point Stability UOP 413
, mg/100ml Distillation Temperature for Recovery @ 85.5 Vol % and 95 Vol % Water
Content 0.05 Vol % max Not more than the Feed Diesel Not less than 40 48.5 2000
Equal to or Not higher than the Feed < 1.6
ATTRIBUTES
UNITS
DESIGN
CAPACITY
MMTPA
2.20
ATTRIBUTES
UNITS
DESIGN
TPUT CATALYSTS TK-10 Quantity Life Feed Processed TK-711 Life Feed Processed RF20
0 Life Feed Processed HC-K Life Cycle Length Feed Processed H2 consumption (SOR/
EOR) Quantity Quantity Quantity
M3/Hr
314.0
MT Years M3/Kg of Cat 5 44.5
MT Years M3/Kg of Cat MT Years M3/Kg of Cat MT Years Years M3/Kg of Cat NM3/M3 O
F fresh Feed 5 2 44.5 182.3/191.2 2 17.8 2 17.8
SWEET DIESEL YIELD(SOR/EOR) GAS TO OIL RATIO OPERATING PARAMETERS FURNACE Effici
ency H2 Partial Pressure Recycle Gas Purity REACTOR-1 Inlet Pressure(SOR/EOR) He
at Duty
Wt% of Fresh Feed NM3/M3 OF FEED
96.9/95 250-500
MMKCal/Hr. % Kg/Cm2 %H2
20.08 91.94 59 Min. 70 Min
Kg/Cm2
102.9/102.4
ATTRIBUTES
UNITS
DESIGN
Inlet Temprature(SOR/EOR) Outlet Temprature(SOR/EOR) Delta P. Across reactor(EOR
) Delta T Across Reactor(EOR) WABT Ist Bed WABT IInd bed Quench Flow REACTOR-2 I
nlet Pressure(SOR/EOR) Inlet Temprature(SOR/EOR) Outlet Temprature(SOR/EOR) Delt
a P Across Reactor(EOR) Delta T Across Reactor(EOR) WABT Ist Bed WABT IInd bed I
st Quench Flow Iind Quench Flow H.P.SEPARATOR Pr.
0
C C
323/370 368/406 3.1 35
0
Kg/Cm2
0
C C C
0
0
Kg/Hr.
20000
Kg/Cm2
0
99.6/99.1 323/372 368/406 8.8 34
C C
0
Kg/Cm2
0
C C
0
Kg/Hr. Kg/Hr. Kg/Cm2
21600 21600 84.5
ATTRIBUTES
UNITS
DESIGN
STRIPPER Pressure Top Temprature Stripping Steam Kg/Cm2
0
8.5 165 6.8
C
MT/Hr.
Utility Summary for DHDT A. Cooling Water : Design Data
Type (Once thru/circulating Sea/Water) Flow Rate (m3/hr) Supply / return tempera
ture (oC) B. Steam
: Circulating Water
: 2480 : 33 / 42 :
Flow rate, (T/hr)
: Generation Consumption in the unit
Net import / export
HP Steam MP Steam LP Steam Operating Pressure & Temperature (Kg/cm2a)/ oC) HP St
eam MP Steam LP Steam Others, if any
: : : 87.0 : : 36.0 / 400 : 11 / 275 : 4.5 / 180 : 98.7 10.6 1.0
98.7 10.6 - 86.0
C.
Fuel
: : i) Heater absorbed duty, (MM Kcal/hr) ii) Heater efficiency
: iii) Heater fired duty (MM Kcal/hr) Or fuel consumed (T/hr) Total Power Consumpt
ion in HGU (KW)
: 2.7
D.
: 9183
PROCESS DESCRIPTION
DHDT is installed for upgradation of Coker Gas Oil as well a
s quality improvement of few diesel components.
The feed is mixed with Hydrogenrich recycle gas & make up Hydrogen after being compressed in respective compres
sor and reheated by exchanging heat with hot reactor effluent. The mixture is fu
rther heated to the desired reactor temperature in a fired heater and is fed to
the Hydrotreater reactor. Hydrotreating reactions are exothermic in nature and h
ence recycle gas is introduced as quench between the beds of the reactor to cool
reaction fluid and redistribute vapour and liquid.
The reactor effluent is cool
ed by heat exchange with feed and recycle gas before it is finally cooled in the
air cooler and then flashed in the separator. The hydrogen rich separator gas i
s scrubbed with Lean Amine in Recycle Gas Amine scrubber to remove H2S, recompre
ssed and combined with make up hydrogen coming from the Hydrogen plant and then
returned to the reactor. Sour water is coalesced and removed from the bottom of
the separator and sent to Sour Water Stripper Unit. The liquid from the separato
r is sent to a stripper via heat exchangers part of the condensed stripper overh
ead is pumped to stripper as reflux and rest is taken out as naphtha product. Th
e uncondensed vapour ex stripper is sent to Amine Absorption Unit. The bottom pr
oduct from stripper gas to storage as hydrotreated gas oil component after cooli
ng.
OIL MOVEMENT & STORAGE

Oil Movement & Storage (OM & S) is an important function of the Production Depar
tment. In Barauni Refinery, OM & S section consists of the following sub section
s:
OM & S - Receipt. OM & S - Despatch LPG Utilities Coke Handling
OM & S PUMPS A. Crude and Intermediate Product are pumped through centrifugal pu
mps. Besides there are booster pumps in the pipelines and transfer pumps to the
marketing. B.Finished Product Pumps of centrifugal type are present to pump the
finished products like SRN, MS, MRN, SKO, HSD, LDO, LSHS, caustic transfer, slac
k and paraffin wax, Phenol Extract / CBFS / FO, LPG Bottling, LPG bulk loading,
LPG Intank pump for bulk loading from Mounded bullets.
TANK WAGON LOADING GANTRY A. White Oil Loading Gantry Maximum 38 number of BG T/
Ws can be placed in one line for the products (SRN/MS/SKO/HSD). 24 numbers of BT
PN T/Ws can be placed in one line. B.Black Oil Loading Gantry It has two rail li
nes, both lines have BG and MG tracks. In this gantry loading of LDO/Phenol Extr
act/LSHS can be done in BG/MG Tank wagons. FO/LDO points are multiple and LSHS/P
henol Extract points are common.
C.Lube Oil Loading Gantry It has two rail lines known as line no. 5 and 6. only
B.G. T/Ws can be loaded in this gantry with CBFS-500, Rubber Extender Oil. Howev
er, none of above products are loaded now in this gantry. LPG Storage in Horizon
tal tanks(bullets), Horton spheres(presently there are four) Horton spheres serv
ice. These are: Two of capacity 300 M3 & Two of capacity 1500 M3 each and 6 nos.
Mounded bullets capacity 1500 M3 each.
UTIITIES
PROCESS COOLING WATER SYSTEM
1.0 2.0 Cooling Water Type water) 2.1 No. of cells 5 (Once through / Both
Circulating fresh water or sea
Min.
Nor.
Max.
2.2
Supply Press. , Kg/Cm2
5.0
2.3
Design wet bulb temp., oC
29.0
2.4
Supply temp., oC
33.0
2.5
Return temp., oC
45.0
-
2.6
Return Press., Kg/Cm2 (a) At the top of cooling tower
0.3
2.9
If any treatment done
Yes
If yes, Detailes
Non -oxidising biocides used.
2.11
Cooling pumps
water
circulating
7 motors
2.11.1
Type
Centrifugal
2.11.2
No. (Working+ standby)
4 working +3 standby
2.11.3
Capacity, M3 / Hr ( Rated / Normal)
3825
2.11.4
Head, Kg/Cm2
5.0
2.11.5
Power
Consumption,
KW
720 kw (each)
(Rated / Normal /
CRU COOLING WATER SYSTEM
1.0
Cooling Water
2.0
Type water)
(Once
through
/ Circulating fresh water
Circulating fresh water or sea
2.1
No. of cells
2
Min.
Nor.
Max.
2.2
Supply Press. , Kg/Cm2 (a)
5.0-6.0
2.3
29.0
2.4
Supply temp., oC
33.0
2.5
Return temp., oC
45.0
2.6
3-5
2.9
Yes
If yes, Detailes
2.10
Cooling water Make up, M3 / Hr
50
2.11
Cooling water circulating pumps

2 nos.
2.11.1
Type
Centrifugal
2.11.2
2.11.3
1200
2.11.4
Head, Kg/Cm2
5.6
2.11.5
Power Consumption, KW (Rated / Normal /
160
BXP COOLING WATER SYSTEM
1.0
Cooling Water
2.0
Type
(Once
through
/ Circulating fresh water
Circulating fresh water or sea water)
2.1
No. of cells
5
Min.
Nor.
Max.
2.2
5.0-6.0
2.3
29.0
2.4
Supply temp., oC
32.0
2.5
Return temp., oC
45.0
2.6
Return Press., Kg/Cm2 (a)
3-5
At
the
top
of
cooling
tower 2.9 If any treatment done Yes
If yes, Detailes
2.10
2.11
5 nos.
2.11.1
Type
Centrifugal
2.11.2
2.11.3
4450
2.11.4
Head, Kg/Cm2
5.1
2.11.5
Power
Consumption,
KW
6.6 (each)
(Rated / Normal /
TPS COOLING WATER SYSTEM
1.0 Cooling Water
2.0
Type
(Once
through
/
Circulating Circulating fresh water
fresh water or sea water)
2.1
No. of cells
3
Min.
Nor.
Max.
2.2
3.5
2.3
29.0
2.4
Supply temp., oC
32.0
2.5
Return temp., oC
40
2.6
2.5
2.7
Blow
Down
Quantity,
M3
/
Hr
75-100
(continuous) 2.8 Cooling water balance, M3 / Hr Total to TPS
2.9
Yes
If yes, Detailes
2.10
75
2.11
3 nos.
2.11.1
Type
Centrifugal
2.11.2
2.11.3
3600
2.11.4
Head, Kg/Cm2
5.1
2.11.5
Power
Consumption,
KW
(Rated
/
450
Normal /
UTILITIES
A gas flare, alternatively known as a flare stack, is an elevated vertical conve
yance found accompanying the presence of oil and gas wells, rigs, refineries, ch
emical plants, natural gas plants, and landfills. They are used to eliminate was
te gas which is otherwise not feasible to use or transport. They also act as saf
ety systems for non-waste gas and is released via pressure relief valve when nee
ded to ease the strain on equipment. They protect gas processing equipments from
being overpressured. Also in case of an emergency situation, the flare system h
elps burn out the total reserve gas. The size and brightness of the resulting fl
ame depends upon how much flammable material was released. Steam can be injected
into the flame to reduce the formation of black smoke. The injected steam does
however make the burning of gas sound louder, which can cause complaints from ne
arby residents. Compared to the emission of black smoke, it can be seen as a val
id trade off. In more advanced flare tip designs, if the steam used is too wet i
t can freeze just below the tip, disrupting operations and causing the formation
of large icicles. In order to keep the flare system functional, a small amount
of gas is continuously burned, like a pilot light, so that the system is always
ready for its primary purpose as an over-pressure safety system. The continuous
gas source also helps diluted mixtures achieve complete combustion.
Flare gas recovery system There are two compressors for recovery of waste flare
gas, compressing the same and put it back to refinery fuel gas header for consum
ption in furnace/ boilers. Capacity of each compressor is 450 NM3/Hr. Water trea
tment Many industries have a need to treat water to obtain very high quality wat
er for demanding purposes. Water treatment produces organic and mineral sludges
from filtration and sedimentation. Ion exchange using natural or synthetic resin
s removes calcium, magnesium and carbonate ions from water, replacing them with
hydrogen and hydroxyl ions. Regeneration of ion exchange columns with strong aci
ds and alkalis produces a wastewater rich in hardness ions which are readily pre
cipitated out, especially when in admixture with other wastewaters.
Treat tment o indus of strial w wastewa ater The d differen types of con nt s nt
amina ation of waste f ewater require a varie of r ety strate egies to remov the
c o ve contamination. . Solids remov s val Most solids c be remove using simple
sedime can ed g e entation techn niques w with the e solids recove s ered as sl
urry or slud dge. Ver fine solids and solids with ry a h densit ties clo to the
dens ose sity of water p pose special pr roblems In such case s. e filtrat tion
or ultrafiltration may be requi n b ired. Al lthough floccu h, ulation may be e
used, using a alum salts or th addition of polyele he ectrolyt tes. Oils a and g
re ease re emoval: API oi il-wate separator er
API avity se eparatio devic desig on ce gned by using Stokes y The A separator i
s a gra Law to define the rise velo o r ocity of oil dro f oplets b based on the
ir density and y
size. T des The sign is based o the specific gravit diffe b on s c ty erence b b
etween the oil and th wast he tewater because that differ r t rence is much smal
ler than t s s r the specif grav fic vity diff ference betwe the suspen e een e
nded so olids and water The d r. suspe ended so olids se ettles to the bottom o
the s o b of separat as a sedime laye tor ent er, the oi rises to top of the sep
arat and the cle il tor d eansed wastew water is the s [3] middle layer betwee t
he o layer and th solid e en oil he ds. Typica ally, the oil lay is skimmed off
an subsequently re-pr yer d nd rocesse or ed dispos of, and the botto sediment l
a sed e om ayer is r removed by a c chain an fligh nd ht scraper (or s similar d
evice) and a sludge p ) s pump. T wat laye is sen to The ter er nt atment consis
t ting usu ually of a Elect tro-flot tation m module f for further trea ional re
emoval of any r o residual oil and then t some type o biolo d to e of ogical ad
diti treatm ment un for remova of und nit al desirab disso ble olved chemical co
mpo ounds.
A typical par rallel plate sep parator Parallel plate separa e ators are similar
to A sep API parators but th incl s hey lude tilted paralle plate assemb d el b
lies (to enhan the degree of oilnce e e -water separation). The parallel plates
pr rovide m more su urface for sus spended oil d drople to c ets coalesce into l
a e arger globules However, the parall plate The g s. e lel es. e result is that
a para t t allel pla sepa ate arator r require signif es ficantly less sp y pac
e th han a conv ventiona API separat to achieve the sam degree of separat al s t
or a me tion.
val radable organ e nics Remov of biodegr
Biodegradable organic mat terial of plant or anim origin is usu f mal ually po o
ssible to t extende conventiona waste ed al ewater treatm ment pro ocesses such
as s a treat using e activa ated slu udge or tricklin filte Prob ng er. blems ca
arise if the wastew an e water is s exces ssively d diluted with wa ashing wate
r o is hig or ghly con ncentra ated suc as ch neat b blood or milk. The pre r T
esence of clea aning ag gents, disinfectants, pestic cides, o antibiotics c have
detrim or can e mental impacts on tre eatmen nt proce esses.
Activa vated sl ludge process p s
Activa ated slu udge is a bioch hemical proces for t ss treating sewag and in g
ge ndustri ial waste ewater t that us air ( oxyg ses (or gen) and micro oorganis
sms to biologic cally oxidiz organ pollutants, produc ze nic cing a w waste slu
dge (o floc) contain or ning the e oxidiz mat zed terial. Trick kling filter pro
ocess
A schematic cross-s section of the contac face of the bed me n e ct edia in a tr
ickling filter
A typical com mplete tricklin filter system t ng r m A tric ckling f filter co o

nsists of a be of ro ed ocks, gr ravel, sl lag, pea moss, or at plastic media ov
er which w a w wastewa ater flo dow ows wnward and con ntacts a layer (or fil of
m lm) microbial slime coveri the bed me e ing edia. Ae erobic c conditio are on
s maintained b force air f by ed flowing through the b or by natur conv h bed b
ral vection of cess inv volves a adsorption of o organic compou unds in the wa a
stewater air. The proc e obial slim laye diffu me er, usion of air int the slime
la f to s ayer to provide e by the micro the ox xygen r required for th biochem
ical oxidat d he tion of the org ganic co ompound ds. The e prod end ducts in nc
lude c carbon dioxide gas, w e water an othe produ nd er ucts of the ox xidation
As th slime layer thicken it be n. he e ns, ecomes difficu for t air to ult the
penet trate th layer and an inner anaerob laye is for he r n bic er rmed. Treat
tment o othe organ of er nics Synth hetic or rganic materials includ m ding sol
vents, paints, pharmaceutic cals, pestic cides, c coking products and so forth c
an be very difficult to tre p h e d t eat. Treat tment m methods are of s ften s
pe ecific t the m to materia being treated. al Metho ods inc clude Advanced Oxid
dation P Processing, dis stillatio ads on, sorption n, vitrification, incine er
ation, chemical imm , mobilisa ation or landf disp fill posal. ials such as some
det tergents may b capable of b s be biologic cal Some materi degra adation and
in such ca s ases, a modifie form of was m ed m stewate treat er tment can c be
use ed. Treat tment o acids and a of s alkalis Acids and alk s kalis ca usually
be ne an eutralis und cont sed der trolled conditions. Neutr ralisatio freq on
quently produces a pre ecipitat that will req te quire tr reatment as a solid re
s sidue th may also be toxic In som case gass may be hat y b c. me es, ses y ed
uiring tr reatmen for the gas stream Some other forms of nt t m. e evolve requ t
reatm ment ar usually requ re uired fo ollowing neutra g alisation n.
Waste streams rich in hardness ions as from de-ionisation processes can readily
lose the hardness ions in a buildup of precipitated calcium and magnesium salts.
This precipitation process can cause severe furring of pipes and can, in extrem
e cases, cause the blockage of disposal pipes.Treatment is by concentration of d
e-ionisation waste waters and disposal to landfill or by careful pH management o
f the released wastewater. Treatment of toxic materials Toxic materials includin
g many organic materials, metals (such as zinc, silver, cadmium, thallium, etc.)
acids, alkalis, non-metallic elements (such as arsenic or selenium) are general
ly resistant to biological processes unless very dilute. Metals can often be pre
cipitated out by changing the pH or by treatment with other chemicals. Many, how
ever, are resistant to treatment or mitigation and may require concentration fol
lowed by landfilling or recycling. Dissolved organics can be incinerated within
the wastewater by Advanced Oxidation Processes.
Quality Control
Modernization and Infrastructure Development Modernization and Renovation of Qua
lity Control Laboratory is under progress. A new laboratory building is under co
nstruction and the old laboratory building is being renovated phase wise. For sm
ooth commissioning and operation of MSQ project and other test facilities, a new
laboratory is being set up.
Carbon, Nitrogen, Sulphur & Chloride Analyser: This
instrument is capable to check these elements in sub ppm level in different pet
roleum products. This is a microprocessor based automatic instrument.
GC Oxygena
tes: This special type of Gas Chromatograph is used to check oxygenates content
in gasoline. This parameter is required to be tested to certify BSIII MS.
Potent
iometric Titration System: It is used for evaluation of Diene content (MAV), Bro
mine number, Bromine index etc. in petroleum products. RON Engine: An advance mo
del RON engine is under final stage of procurement/arrival.
Developmental Studies
Viscosity grade Bitumen: BIS introduced new Specifications
for Bitumen (IS 73:2006) implemented where some new specification parameters li
ke viscosity at different temperature and vacuum were incorporated. Test facilit
ies for these new parameters were developed. Antioxidant Dose Optimization Study
: To optimize the dosing rate of anti oxidant in MS blending component ex-FCCU,
a study was conducted. Effectiveness, optimum dosing quantity, reaction time of
antioxidant was determined and informed to production for implementation.
BS III
HSD Certification: Till date HSD produced in BR is certified under BSII specifi
cation. Test facilities have been developed to certify HSD under BSIII specifica
tion. Few batches of BSIII HSD have already been certified. BS III MS Certificat
ion: Test facility has been developed for carrying out additional test required
for certification of BSIII MS. BSIII MS Production: Blend study for production o
f BSIII MS before MSQ commissioning with imported isomerate & MTBE.
CLO up-grada
tion: CLO is a low demand / low value stream ex-FCCU. It has certain disadvantag
es like high viscosity, high density, high ash etc. Blend study was conducted to
find out the possibility of using CLO as FO blending component. IFO up-gradatio
n & Certification of FO: To find the possibility of selling IFO as Fuel Oil, sam
ples from all IFO tanks were collected and tested for all Fuel Oil parameters. C
ertification of F.O., a new product is done w.e.f. April 2009. Trial runs conduc
ted to assess FO/IFO quality .Further blend study and optimization of PPD doses
were done to meet certification of winter grade F.O. ATF Production: ATF produce
d from different crude mix was found to be failing in Acid number and JEFTOT tes
t. Study was conducted to reduce acid number by caustic wash followed by water w
ash. Commissioning of DHDT 3rd Reactor: Laboratory support was given by way of c
ontinuous product quality evaluation for commissioning of DHDT 3 reactor.
DHDT P
GTR: For performance evaluation, Quality of all rundown streams was evaluated du
ring DHDT PGTR.
rd
Loss Control (I)Quality Give Away (QGA) Prevention: To generate awareness among
all concerned, QGA value in terms of money was calculated for all certified tank
s and circulated. Significant improvement has taken place in this field. (II)Por
table Flue Gas Analyser: Two portable Flue Gas Analysers were procured and put i
n service for in-situ analysis of flue gas to improve furnace efficiency. (III)L
PG Loss Control: Fuel gas was checked on regular basis for LPG slippage. Environ
mental Management
Effluent Quality Monitoring under new MINAS
Monitoring of Raw
water and drinking Quality Cost Reduction in Utility Consumption Use of hydrogen
& nitrogen generator in place of cylinders
Use of Orsat apparatus in place of d
ragger tube for checking H2S content Use of low cost Argon in place of Helium fo
r operation of low level Sulphur and chloride analyser.

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Indian Oil Corporation Ltd.

Down the memory lane

Vacuum distillation increases the relative volatility of the key components in m

STABILIZER COLUMN:-Unstabilised gasoline is pumped to 16th/20/24th tray of Stabi

Wide Cut Short Residue

LPG RECOVERY UNIT ( LRU )

C CRU(C ALYTI RE RMIN UN CATA IC EFOR NG NIT)

2: The isome e erizatio of no on ormal paraffin to is p ns soparaf ffins as exem

BRIEF PROCESS DESCRIPTION: (I)NAPHTHA SPLITTER UNIT (NSU) :

vap pourizat tion occ curs in 02-FF-002. R Reboilin is controlled by 02 ng d 2-T

FLUIDISED CATALYTIC CRACKING

Regenerator flue gas

condensation of aromatics, grouping a large number of these compounds to such a

HYDROGEN GENERATION UNIT

first desulphurised over a desulphurisation catalyst where, in presence of hydro

(SRN C5-90OC CUT)

Heat recovered, (MM Kcal/hr)

DIESEL HYDRO EATI D H OTRE ING UNIT ( D T DHDT ) T

Case I Capacity MTPA (BPSD) 2.2 (47460)

OIL MOVEMENT & STORAGE

Cooling water circulating pumps

A typical com mplete tricklin filter system t ng r m A tric ckling f filter co o

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