IOCL Mathura

Summer Training Report

Submitted By:

Pulkit Agarwal
2014UCH1692
PREFACE
Industrial training is the beginning of students journey in the corporate world. Not
only does it provide the insights about the industry concerned, it also bridges the
gap between theory and practical knowledge. We were fortunate that we were
provided with an opportunity of undergoing Industrial Training at INDIAL OIL
CORPORATION LTD., MATHURA, one of the leading refineries in India. The
experience gained during this short period was fascinating to say the least. It was a
tremendous feeling to observe the operation of different equipments and processes.

It was overwhelming for us to notice how such a big refinery is being monitored
and operated with proper coordination to obtain the desired results. During our
training we realized that in order to be successful process engineer, one needs to
possess sound theoretical knowledge along with the acumen for effective
practical application of theory. Thus, we hope that this industrial training serves
as a stepping stone for us and helps to be successful in future.

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ACKNOWLEDGEMENT

I would like to express my gratitude to all those who gave me the possibility to
complete this training. I want to thank the department of training and
management of Mathura refinery for giving me permission to commence this
training. I have furthermore to thank the officers of production for giving me
such knowledge about the plant and the production process.
It is really great opportunity for me to have learnt many more of refinery. I am
deeply indebted to Mathura Refinery for giving such opportunity to students to
complete their vocational training and providing such intriguing environment to
visit the plant and learn about the refinery. I owe a deep sense of gratitude to the
officers who supported me throughout the training. Their keen interest on me at
every stage of my training, prompt inspirations, timely suggestions with
kindness, enthusiasm and dynamism have enabled me to complete my training. It
is a genuine pleasure to express my deep sense of thanks and gratitude to:
Mr. DALIP SINGH (DM-T&D)
Mr. MAHATO C S (Sr. Production Manager)
Mr. A K JAIN (CPNM)
Mr. AAKASH PURI (Sr. Engineer, FCCU)

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Introduction:

Indian OIL is not only the largest commercial enterprise in the country it is
the flagship corporate of the Indian Nation. Besides having a dominant
market share, Indian oil is widely recognized as Indias dominant energy
Brand and customers perceive Indian oil as a reliable symbol for high
quality products and services. Benchmarking quality, quantity and service
to world class standards is a philosophy that Indian Oil adheres to ensure
that customers get truly global experience in India. The continued
emphasis is on providing fuel management solutions to customers who
can then benefit from our expertise in efficient sourcing and least cost
supplies keeping in mind their usage patterns and inventory management.
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 Fortune "Global 500"
listing. The oil concern is administratively controlled by India's Ministry of
Petroleum and Natural Gas, a government entity that owns just over 90 percent of
the firm. Since 1959, this refining, marketing, and international trading company
served the Indian state with the important task of reducing India'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 firm owns and
operates seven of the 17 refineries in India, controlling nearly 40 percent of the
country's refining capacity.

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List of Processing Units:
Crude distillation Unit (CDU)
Atmospheric & Vacuum distillation Unit (AVU)
Fluidized catalytic cracking unit (FCCU)
Vis-breaker Unit (VBU)
Continues catalytic Reforming unit
(CCRU) Merox Unit (Mercaptan Oxidation)
Propylene recovery unit (PRU)
Bitumen blowing Unit (BBU)
Diesel hydro desulphurization unit (DHDS)
Diesel hydro treatment unit (DHDT)
Once through hydro cracker unit
(OHCU) Hydrogen generation unit (HGU)
Amine recovery unit (ARU)
Sulfur recovery unit (SRU)
Motor spirit quality unit
(MSQU) Prime G
Naphtha splitter unit (NSU)
Naphtha Hydro-Treater unit
(NHTU) Nitrogen Generation unit

Other utilities include:

Effluent treatment plant
(ETP) Capacitive power plat
Air monitoring Station
Ecological Park

& OM&S -1 and OM&S -2

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Process Flow of Mathura Refinery
Major Products:
Indane Gas
Auto Gas
Natural Gas
Petrol/Gasoline
Diesel/Gas oil ATF/Jet
fuel SERVO lubricants
& greases Marine Fuels
& Lubricants Kerosene
Bitumen.

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 Fluidized Catalytic Cracking Unit (FCCU)
Objective:
To convert Heavy Vacuum Gas Oil to valuable distillates like LPG,
Gasoline, Diesel by catalytic cracking in fluidized bed.
Feed:
HVGO (Heavy vacuum gas Oil) from VBU + OHCU (Once through
Hydrocracker Unit) Bottom.
Catalyst: Silica & Alumina Zeolite Structure.
FCCU Product Yields:
Sr. No. Products wt%
1. Gas 2.3
2. LPG 14.7
3. Gasoline 41.3
4. HN 21.3
5. LCO 11
6. HCO 0
7. CLO 10.9
8. Coke 4

Operating conditions:
Temperature range: 490-550 C

Pressure: 2-3 kg/cm2

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Plant Overview:
The revamped FCC is designed to operate at the charge rate of 1.5 MMTPA
which was originally designed to operate at a charge rate of 1.0 MMTPA.
Main Feed to the FCC Unit is the Nigerian heavy vacuum gas oil (HVGO) and
OHCU Bottoms. The Nigerian HVGO is considered to be of moderate cracking
quality and is relatively low in sulphur, but high in nitrogen. The OHCU
Bottoms is the other main feedstock. It is of high quality as a cracking feed
and is extremely low in sulphur, nitrogen, metals, and carbon residue.

The unit requires following types of catalyst:

Fresh catalyst
Equilibrium Catalyst
ZSM-5 additive catalyst
CO promoter additive catalyst

Following chemicals shall be used for FCC plant:

Flushing Oil:
Corrosion Inhibitor:
Antifoaming Agent:
Tri Sodium
Phosphate: Lube Oil:
Hydraulic Oil:
Process Overview:
The Fluidized Catalytic Cracking Process converts heavier hydrocarbons
into lighter more valuable hydrocarbon products at a high temperature and
moderate pressure in the presence of finely divided silica/alumina catalyst.
In the course of cracking, non-volatile carbonaceous material commonly
referred to as coke is deposited on the catalyst.
The coke laid down on the catalyst acts to deactivate the catalytic cracking activity
by blocking access to the active catalytic sites. In order to regenerate the catalyst
activity, the coke deposited on the catalyst is burnt off with air in regenerator.

The ability of the catalyst is to flow easily between the reactor and regenerator
when fluidized with an appropriate vapor phase. The vapor phase on the reactor
side is vaporized hydrocarbon and steam, while air and combustion gases on the
regenerator side. In this way, fluidization permits hot regenerated catalyst to
contact fresh feed. The hot catalyst vaporizes the liquid feed and catalytically
cracks the vaporized feed to form lighter hydrocarbons.

After the gaseous hydrocarbons are separated from the spent catalyst, the
hydrocarbon vapor is fractionated into the desired product streams. The
separated spent catalyst flows via steam fluidization from the reactor to the
regenerator where coke is burned off & the catalyst restores its activity.
In the course of burning the coke, a large amount of heat is liberated. Most of
the heat of combustion is absorbed by the regenerated catalyst and is carried
back to reactor to supply the heat required. The ability to continuously
circulate fluidized catalyst between the reactor and the regenerator allows the
FCC unit to operate efficiently as a continuously process.

FCC is often the heart of modern refinery because of its adaptability

to changing feedstock & product demands and because of the high
margins that exist between FCC feedstock and converted products.

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System Description:
In the newer designs for Fluid Catalytic Cracking Unit, cracking takes place
using a very active zeolite-based catalyst in a short-contact time vertical or
upward sloped pipe called the "riser". Pre-heated feed is sprayed into the base
of the riser via feed nozzles where it contacts extremely hot fluidized catalyst
at 1230 to 1400 F (665 to 760 C). The hot catalyst vaporizes the feed and
catalyzes the cracking reactions that break down the high molecular weight oil
into lighter components including LPG, gasoline, and diesel. The catalyst-
hydrocarbon mixture flows upward through the riser for just a few seconds
and then the mixture is separated via cyclones. The catalyst-free
hydrocarbons are routed to a main fractionator for separation into fuel gas,
LPG, gasoline, light cycle oils used in diesel and jet fuel, and heavy fuel oil.
During the trip up the riser, the cracking catalyst is "spent" by reactions which
deposit coke on the catalyst and greatly reduce activity and selectivity. The
"spent" catalyst is disengaged from the cracked hydrocarbon vapors and sent
to a stripper where it is contacted with steam to remove hydrocarbons
remaining in the catalyst pores. The "spent" catalyst then flows into a
fluidized-bed regenerator where air (or in some cases air plus oxygen) is used
to burn off the coke to restore catalyst activity and also provide the necessary
heat for the next reaction cycle, cracking being an endothermic reaction. The
"regenerated" catalyst then flows to the base of the riser, repeating the cycle.
The gasoline produced in the FCC unit has an elevated octane rating but is less
chemically stable compared to other gasoline components due to its olefin
profile. Olefins in gasoline are responsible for the formation of polymeric
deposits in storage tanks, fuel ducts and injectors. The FCC LPG is an important
source of C3-C4 olefins and iso-butane that are essential feeds for the alkylation
process and the production of polymers such as polypropylene.
In this process Heavy Gas Oil cut (Raw Oil) from Vacuum Distillation Section
of AVU is catalytically cracked to obtain more valuable light and middle
distillates. The present processing capacity of the unit is about 1.48 MMT/Yr.
It consists of the following sections:
Pre-heat section
Gas concentration section
Fractionation section
Catalytic (Regenerator) section
Cracking (Reactor) section
CO boiler
The unit is designed to process two different types of feed i.e.
Arab Mix HVGO and Bombay High HVGO.
Significance of Gas concentration section:
In Gas concentration section the separation of LPG and stabilization
of naphtha is achieved in steps as follows:
The overhead gas is compressed by WGC to about 13 kg/cm 2. The
LPG component in the compressed gas is absorbed by overhead
naphtha in the absorber and send to stripper.
The lighter ends C1 and C2 are stripped off and the stripper
bottom is send to debutanizer.
The debutanizer separates the LPG and stabilize the naphtha.
Key aspects of Operation and Maintenance:
Catalyst circulation is established by fluidization.
Handling of hydrocarbon and air side by side at very high
temperature (500-700 C).
Reactor and regeneration section is separated by delicate pressure balance.
Coke deposited on the catalyst is burned off in regenerator at 650 C.
Separation of fine catalyst in hydrocarbon vapors and in
flue gas by cyclones.
Erosion is a common phenomenon in Cyclone and slide Valves.

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FCCU flowsheets:

Complete Flowsheet of FCC Unit:

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References:
1. IOCL MANUALS
2. www.petroleumrefining.com, Petroleum Refining Engineering Website.
3. Unit Operations of Chemical Engineering by Dennis C. Prieve, Pittsburg.
4. www.engineeringtoolbox.com, Chemical Engineering Website
5. Petroleum Refining by James H. Gary, Colorado