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Project Report: Nikitha Saripalli National Institute of Technology, Warangal
Project Report: Nikitha Saripalli National Institute of Technology, Warangal
By
NIKITHA SARIPALLI
NATIONAL INSTITUTE OF TECHNOLOGY, WARANGAL
CERTIFICATE
HPCL HPCL
Visakhapatnam Visakhapatnam
ACKNOWLEDGEMENT
I have taken efforts in this project. However, it would not have been
possible without the kind support and help of many individuals and HPCL
officials . I would like to extend my sincere thanks to all of them.
I am highly indebted to Mr.Satya Rao(Chief Manager –Training) and Mr.
Udit nandi ( Manager- Technical Department- VR) . My sincere thanks to
Mrs N.Richa (MS block) , Mrs K .Shailaja(FCCU ) , Mr Kailash Rathod
(Utilities ), Mr A.V.B.S Srinivas & Mr Sudheer (CDU) and Mr Anshul
Arora (DHDS) for their guidance and constant supervision as well as for
providing necessary information regarding the project & also for their
support in completing the project.
I would like to express my gratitude towards member of HPCL for their
kind co-operation and encouragement which helped me in completion of
this project.
I would like to express my special gratitude and thanks to industry persons
for giving me such attention and time.
My thanks and appreciations also go to my colleague in developing the
project and people who have willingly helped me out with their abilities.
INDEX
Topic Pg no.
ÿCover Page 1
ÿCertificate 2
ÿAcknowledgement 3
ÿAbbreviations 5
ÿCompany profile 6
ÿTechnical-PAD activities 7
ÿOil storage and movement 8
ÿCrude oil and petroleum refinery process 9
ÿProduct and its specifications 15
ÿProduction-primary unit-CDU 20
ÿSecondary unit- FCCU 25
ÿTreating units- DHDS 32
ÿMS bock 39
ÿPower and Utilities 53
ABBREVIATIONS
SR : Short residue
DM : Demineralised
PP : Power plant
COMPANY PROFILE
ABOUT VISAKH
REFINERY
HPCL-VR is commissioned with an installed capacity of 0.675 MMTPA in
1957 with a Crude distillation unit expanded to 1.5 MMTPA with various
modifications. Later capacity was increased with commissioning 2 more units
of 3 MMTPA each to 7.5 MMTPA. Crude processing capacity is revised to 8.33
MMTPA after various modifications like PFDs in CDUs, FCC unit, offsite
facilities for online bending. A maximum refining capacity of 9.24 MMTPA is
achieved in the refinery. This refinery can process both indigenous and
imported crude as raw material.
TECHNICAL- PAD ACTIVITIES
1. OM &S
2. PRODUCTION
3. POWER AND UTILITIES.
OIL MOVEMENT AND
STORAGE
3. Storage
There are floating roof tanks and cone roof tanks for storage of lighter and heavier
hydrocarbons. Line blending facilities are provided in addition to blending facilities
at storage tanks.LPG used to be stored in Horton spheres. However with the
commissioning of mounded storage total LPG from the refinery is being stored in
LPG mounded storage.
4. Dispatch
Product movement is done through rail, road, pipelines, tankers. Products are
pumped to terminals located nearby refinery for onward distribution. Tankers are
positioned at western arm of inner harbour.
CRUDE OIL
It is a naturally occurring, toxic, flammable liquid consisting of a complex mixture of
hydrocarbons of various molecular weights, and other organic compounds, that are found in
geologic formations beneath the earth’s surface.
Another Definition:
Crude oil is a mixture of hydrocarbon molecules, which are organic compounds of carbon
and hydrogen atoms that may include from one to 60 carbon atoms. The refining process
uses chemicals, catalysts, heat, and pressure to separate and combine the basic types of
hydrocarbon molecules naturally found in crude oil into groups of similar molecules. The
refining process also rearranges their structures and bonding patterns into different
hydrocarbon molecules and compounds. Therefore it is the type of hydrocarbon (paraffinic,
naphthenic, or aromatic) rather than its specific chemical compounds that is significant in the
refining process. In the reservoir, it is usually found in association with natural gas, which
being lighter forms a gas cap over the petroleum, and saline water, which being heavier than
most forms of crude oil, generally sinks beneath it.
∑ Paraffin (CnH2n+2 )
∑ Olefin (CnH2n)
∑ Naphthenes (CnH2n-2)
∑ Aromatic (CnH2n-6)
There are certain amounts of non hydrocarbons that are also present in the crude oil:
∑ Sulphur Compounds
∑ Oxygen Compounds
∑ Nitrogen Compounds
∑ Trace Metals
∑ Salts
∑ Carbon Dioxide
∑ Naphthenic Acid
Major Refinery Products :
1. Gasoline
2. Kerosene
4. Distillate Fuels
5. Residual Fuels
7. Solvents
8. Petrochemicals
9. Lubricants
1. Arab mix
2. Mumbai High
Specific gravity at 15/15 Deg C : 0.8282
Density, Kg/litre at 15 Deg C : 0.8278
API gravity at 15 Deg C : 39.35
RVP, Kg/sq.cm at 38 Deg C : 0.34
Pour point, Deg C : +30.0
Kinematic viscosity (cst) at 37.8 Deg C : 3.75
Kinematic viscosity (cst) at 48 Deg C : 3.28
Kinematic viscosity (cst) at 50 Deg C : 2.24
Water content % wt : 0.4
Salt content % wt : 0.0032
Sulphur total % wt : 0.17
Nitrogen total % wt : 0.015
Carbon residue(Conradson ), % wt : 1.2
Asphaltenes, % wt : 0.28
Ash content % wt : 0.01
Wax content % wt : 10.6
Congealing point of wax, Deg C : 58.0
Water and sediments by centrifuge, % vol : 0.2
Total acidity, mg KOH/gm : 0.15
Inorganic acidity, mg KOH/gm : nil
Characterisation factor, KUOP : 11.7
Listed below are 5 categories of general refinery processes and associated operations:
1.Separation processes
a. Atmospheric distillation
b. Vacuum distillation
c. Light ends recovery (gas processing)
a. Hydrodesulfurization
b. Hydrotreating
c. Chemical sweetening
d. Acid gas removal
e. Deasphalting
5.Auxiliary facilities
a. Boilers
b. Waste water treatment
c. Hydrogen production
d. Sulfur recovery plant
e.Cooling towers
f. Blowdown system
g. Compressor engines
PRODUCTS AND THEIR
SPECIFICATIONS
The product range of refinery includes :
1. LIGHT DISTILLATES
Constitutes 22 % on crude basis.
a. PROPYLENE:
Propylene also known as propene is the second most important starting product in
the petrochemical industry after ethylene. It is the raw material for a wide variety of
products. Manufacturers of the plastic polypropylene account for nearly two thirds of
all demand. The propylene produced in VR is mainly used in APCL. The propylene
produced has following specifications:
Purity: 95% by wt.
Total sulfur: 5%
Uses : As a petrochemical feedstock in polymer industry.
b. LPG
LPG is basically a flammable mixture of propane and butane. It has
wide variety of uses ranging from domestic purposes to locomotive fuel.
The LPG produced in VR is mainly used in cooking purposes in houses.
VR produces LPG of following specifications:
C5 and higher Hydrocarbons: 2.5%
Total sulphur: 150 ppm
c. MOTOR SPIRIT:
Motor spirit commonly known as petrol is basically a blended product of
many hydrocarbons. It is mainly used as fuel in low locomotives. The
motor spirit produced in VR has following specifications:
Density: 720-775 kg/m3
Research octane number: 91 min
Total sulfur: 150 ppm
Lead content: 0.005 g/ml
Benzene: 1% by vol
2. MIDDLE DISTILLATES
Constitute 52 % on crude basis
d. KEROSENE
Kerosene is one of the major combustible liquids which has wide uses in our daily
life. It is mainly used in cooking purposes. VR produces kerosene of following
specifications:
Smoke point: 18 mm
Total sulfur: 0.25% by wt
Flash point: 35 0C
Uses: As domestic cooking fuel
e. DIESEL:
Diesel is also a blended product like motor spirit. It is mainly used in transportation
purposes. It is used as fuel in higher locomotives.
Cetane index: 46 min
Flash point: 35 0C
Kinematic viscosity: 2-5 cSt
Density: 820-845 kg/m3
Total sulphur: 350 ppm
Water: 0.055 by vol
Uses: As transportation fuel and in power generation
3. HEAVY ENDS
Consists of 18 % crude basis.
g. FUEL OIL
Water : 1% by vol
Asphaltenes : 10% by wt
Kinematic viscosity : 80-370 cSt
Sulphur : 4% by wt
Pour point : 27 0 C
Uses : As industrial fuel.
i. BITUMEN
Water : 0.2 % by vol
Penetration point : 30
Penetration : 30-40,60-70,80-100.
Softening point : 40-55 0 C
Flash point : 175 0 C
Uses : In road paving.
The specifications of diesel and gasoline to be produced is :
Specifications of Diesel
Existing Bharat Stage II EURO III EURO IV
Sulfur, PPMW Max 2500 500 350 50 (2005)
10 (2011)
Cetane Number, Min 48 48 51 51
Poly aromatics % Max No Spec No Spec 11 11
Density Kg/M3 820-860 820-860 820-845 820-845
Distillation
T 85 Max 350 350 360 360
T 95 Max 370 360 No Spec No Spec
Gasoline Specifications
Present EURO II EURO III EURO IV
10 (2011)
5 for rest
%Aromatics, max. - - 42 35
%Olefins, max. - - 18 18
PRODUCTION
This includes:
1. CDU
2. FCCU
3. DHDS
4. MSBLOCK
CRUDE DISTILLATION UNIT
(CDU)
It is a primary process unit and consists of CDU I , II, III .
MAJOR EQUIPMENT:
Desalter, Atmospheric column, Atmospheric furnace, Vacuum furnace, Vacuum column,
Preheat exchangers/coolers.
PROCESS:
Reduced crude oil is sent as feed to vacuum distillation unit. The feed is
preheated in fired heater furnace and the vacuum is achieved with the help of set
ejectors. The different fractions obtained are Vacuum diesel, Low vacuum gas
oil, Heavy vacuum gas oil , Short residue.
SR is sent to bitumen blowing unit or visbreaking unit. Gas oils are sent to FCC
units.
1. DESALTING:
Crude oil often contains water, inorganic salts, suspended solids, and water-soluble
trace metals. As a first step in the refining process, to reduce corrosion, plugging, and
fouling of equipment and to prevent poisoning the catalysts in processing units, these
contaminants must be removed by desalting (dehydration).
Here electrical desalting process is applied. The oil phase and aqueous phase is
separated with the help of a strong electric field. Electric Desalting is the application
of high-voltage electrostatic charges to concentrate suspended water globules in the
bottom of the settling tank. Surfactants are added only when the crude has a large
amount of suspended solids.
The crude received from the off-site storage is pumped by Unit charge pumps. Crude
is preheated to desalting temperature of 129-136 deg Celsius in successive heat
exchangers, utilizing relatively low temperature fluids such as heavy naphtha, vacuum
diesel, kerosene product, heavy diesel product respectively.
Stripped water from sour water stripper and DHDS-SRU is used for desalting. On
mixing, the undesirable salts present in the crude get dissolved in the wash water and
hence get separated from the crude.
Brine from the desalter is sent to sour water stripper unit and then transferred to ETU.
2. Separation Processes
The first phase in petroleum refining operations is the
Separation/Fractionation/Distillation of crude oil into its major constituents using 3
petroleum separation processes: atmospheric distillation, vacuum distillation, and
light ends recovery (gas processing).
3. Fractionation
The separation of crude oil in atmospheric and vacuum distillation towers into groups
of hydrocarbon compounds of differing boiling-point ranges (relative volatility) called
"fractions" or "cuts."
5. Vacuum Distillation
In order to further distil the residuum or topped crude from the atmospheric tower at
higher temperatures, reduced pressure is required to prevent thermal cracking. The
process takes place in one or more vacuum distillation towers. The principles of
vacuum distillation resemble those of fractional distillation and, except that larger-
diameter columns are used to maintain comparable vapour velocities at the reduced
pressures, the equipment is also similar.
Topped crude withdrawn from the bottom of the atmospheric distillation column is
composed of high boiling-point hydrocarbons. When distilled at atmospheric
pressures, the crude oil decomposes and polymerizes and will foul equipment. To
separate topped crude into components, it must be distilled in a vacuum column at a
very low pressure and in a steam atmosphere. In the vacuum distillation unit, topped
crude is heated with a process heater to temperatures ranging from 370 to 425°C (700
to 800°F). The heated topped crude is flashed into a vacuum distillation column
operating at absolute pressures ranging from 350 to 1400 kilograms per square meter
(kg/m2). In the vacuum column, the topped crude is separated into common boiling-
point fractions by vaporization and condensation.
Stripping steam is normally injected into the bottom of the vacuum distillation column
to assist the separation by lowering the effective partial pressures of the components.
Standard petroleum fractions withdrawn from the vacuum distillation column include
lube distillates, vacuum oil, asphalt stocks, and residual oils. The vacuum in the
vacuum distillation column is usually maintained by the use of steam ejectors but may
be maintained by the use of vacuum pumps.
PLANT CAPACITIES
CDU I
Design capacity : 1.8 MMTPA
Actual feed rates : 300 to 330 m3/hr
CDU II
Design capacity : 3.1MMTPA
Actual feed rates : 500 to 550 m3/hr
CDU III
Design capacity : 3.4 MMTPA
Actual feed rates : 540 to 560 m3/hr
FLUID CATALYTIC CRACKING
UNIT
It is one of the secondary processing unit.
CRACKING
Cracking involves the decomposition of heavier hydrocarbon feedstocks to lighter
hydrocarbon feed stocks.
Cracking can be carried out to any hydrocarbon feedstock but it is usually applied for
vacuum gas oil (VGO).
Cracking can be with or without a catalyst.
When cracking is carried out without a catalyst higher operating temperatures and pressures
are required. This is called as thermal cracking. This was the principle of the old generation
refineries.
Now a days, cracking is usually carried out using a catalyst. The catalyst enabled the
reduction in operating pressure and temperature drastically.
CRACKING CHEMISTRY
1. Long chain paraffins converted to olefins and olefins.
2. Straight chain paraffins converted to branched paraffins.
3. Alkylated aromatics converted to aromatics and paraffins.
4. Ring compounds converted to alkylated aromatics.
5. Dehydrogenation of naphthenes to aromatics and hydrogen.
6. Undesired reaction: Coke formation due to excess cracking.
7. Cracking is an endothermic reaction.
CATALYST
Acid treated silica-alumina was used as catalyst . 20 – 80 mesh size catalysts used for FCCR
and 3–4 mm pellets used for MBRs. During operation, poisoning occurs with Fe, Ni, Vd and
Cu.
EQUIPMENT
The major equipment are regenerator, reactor, main fractionators, primary absorbers, sponge
absorbers, main air blower, wet gas compressor, De butaniser, stripper.
PROCESS DESCRIPTION
The main process technology consists of two flow sheets namely the cracking coupled with
main distillation column and stabilization of naphtha.
The cracking reaction is mainly converting long chain, high molecular compounds to light
weight products for maximisation of CRN and LPG production by value addition of gas oils.
This process employs a catalyst of silica alumina based zeolite in form of very small
spherical particles which behaves as a fluid when aerated with vapour/air .
Vacuum gas oil from vacuum column is pumped to furnace for achieving the desired
temperature.
Fresh feed is mixed with hot regenerated catalyst and enters the reactor at base of riser where
it gets vaporized at the reactor temperature by the hot catalyst. The gas oil commences to
crack immediately after coming in contact with hot catalyst in riser and continues until the oil
vapours are disengaged from the catalyst in the reactor.
Coke which is generated in the cracking reaction gets deposited on the circulating catalyst in
the reaction zone and the spent catalyst flows from the reactor to regenerator, where coke is
burnt off, by air. The flue gases leaving from the top goes to CO boiler where steam is
generated.
Vapours from reactor are fractionated in fractionation section into recycle gas oil that returns
to reactor and products like light and heavy cycle oil fractions are routed to blending pools,
Clarified oil, unstabilized naphtha undergoes further treatment to satisfy the environmental
norms and the sent to storage and dispatch.
2. Reactor
The basic principle of FCCR is to enable the fluidization of catalyst particles in the
feed stream at desired pressure and temperature.
Another issue for the FCCR is also to regenerate the catalyst by burning off the coke i
air. Therefore, the reactor unit should have basically two units namely a
reactor(FCCR) and a catalyst regenerator(CR). The FCCR consists essentially of two
important components in a sophisticated arrangement. These are the riser and the
cyclone unit assembled in a reactor vessel. Riser: in a riser(long tube), the feed is
allowed to get in contact with the hot catalyst. The hot catalyst is enabled to rise
through the lift media in the riser. The lift media is usually steam or light hydrocarbon
gas. The riser contact time is about 250 milli seconds. The riser is eventually
connected to cyclone units. The catalyst n the vessel is subjected to stream stripping
in which direct contact with steam is allowed to remove hydrocarbons from catalyst
surface.
3. Catalyst Regenerator(CR)
The spent catalyst is sent to a regenerator, where the coke is burned off in air. This
combustion also serves to heat the catalyst The hot regenerated catalyst is then
returned to the riser. Catalyst temperature raised to620 to 750 0C. Lower catalyst
temperature gives partial combustion to CO and needs post combustion. Higher
catalyst temperature gives complete combustion. Flue goes 600 to 760 oC and to 1 to
1.7 bar. Heat recovery from flue gas for steam generation. The spent catalyst which is
relatively cold enters the regenerator unit. Here, air enters the vessel through a sparger
set up. The catalyst is subsequently burnt in the air. His enables both heating the
catalyst(which is required to carry out the endothermic reaction) and removing the
coke so as to regain the activity of the coke. The catalyst + air after this operation will
enter the cyclone separator unit. Unlike the FCCR, the CR does not have a riser.
Therefore, air enters a dense phase of catalyst and also enables the movement of the
catalyst to a dilute phase of catalyst + air. The cyclone separators separate the flue
gas and catalyst as a fluid operation . The activity regained catalyst is sent to the riser
through a pipe. During this entire operation, the catalyst temperature is increased to
620 – 750 0C. The flue gas is obtained at 600- 760 0 C and is sent for heat recovery
unit to generate steam.
4. Naphtha stabilization
The naphtha obtained is unstabilized, as it consists of various hydrocarbons. It is
therefore subjected to stabilized by continued processing.
The slurry enters a phase separation unit which separates decant oil and a heavier
product. The heavier product is recycled back to cracking reactor. The unstabilized
naphtha subsequently enters a unsaturates gas plant. In the unsaturates gas plant, the
gas obtained from the main distillation column is sent to a phase separator. The phase
separator separates lighter hydrocarbons from heavier hydrocarbons.
The phase separator is also fed with the unstabilized naphtha. The unstabilized
naphtha from the main column is first fed to a primary absorber to absorb heavier
hydrocarbons in the gas stream emanating from phase separator. The gas leaving the
primary absorber is sent to secondary absorber where light gas oil from main
distillation column is used as a absorbent to further extract any absorbable
hydrocarbons into light gas oil. Eventually, the rich light gas oil enters the main
distillation column. The naphtha generated from the phase separator is sent to
stripping to further consolidate and stabilize naphtha. The stabilized naphtha is further
subjected to distillation in debutanizer and depropanizer units. The debutanizer unit
removes butanes and lower hydrocarbons from the naphtha. The naphtha obtained as
bottom product in the debutanizer is termed as debutanized stable naphtha or gasoline
.The butanes and the other hydrocarbons are sent to a depropanizer unit where butanes
are separated from propanes and other lighter hydrocarbons. Thus, butanes are
obtained as lower product and propanes along with other lighter hydrocarbons are
obtained as the top product in the depropanizer unit.
ADVANTAGES OF FCC
Heat is efficiently used.
Temperature is controlled.
Catalyst regeneration also controlled.
PLANT CAPACITIES
FCCU -1:
Unit design capacity = 0.95 MMTPA
Unit actual capacity = 1.2 MMTPA
FCCU-2:
Unit design capacity = 0.97 MMTPA
Unit actual capacity = 0.8 MMTPA
PROUCTS:
Fuel gas, LPG, Naphtha, Light Cycle oil, Heavy Cycle Oil, Clarified Oil, Sour water,
Slop.
Vis breaking unit
It is one of the secondary processing units
EQUIPMENT
Furnace, soaker, main fractionators, compressor, stabiliser, sponge absorber.
Process
Vacuum residue from vacuum column after preheating is heated to desired temperature in
fired heater furnace. Streams coming out of furnace are routed to soaker drum for completing
visbreaking reaction. The soaker effluent streams are routed to fractionators column after
quenching by gas oil generating LPG, naphtha, Gas oil, VisTar.
Plant capacities
Design capacity : 1.0 MMPTA
Feed rate : 110 m3/hr
Process
Hot vacuum bottoms is cooled to 230 oC in steam generator before entering bitumen
converter where air is blown. Reaction is exothermic and heat is recovered from injecting
steam. Different grades of bitumen are obtained by improving penetration.
Plant capacities
Design capacity : 0.225 MMPTA
Feed rate : 30 m3/hr
DIESEL HYDRO
DESULPHURISATION UNIT
(DHDS):
It is a treating unit.
Objective of DHDS unit is to supply high speed diesel with 20 ppm wwt sulphur content with
a capacity of 2.4 MMTPA. The units is set up to remove sulphur from diesel.
PROCESS:
The sulphur compounds present in the diesel is removed in the presence of hydrogen
and catalyst in the reactor maintained at desired temperature and high pressure. H2S
generated in the process is removed after amine treating in SRU.
It consists of two important process-
∑ Pre de-sulphurisation i.e. reduction of sulphur content from 1000 ppm to 10 ppm
∑ And then reduction of sulphur content to less than 0.5 ppm
PROCESS:
Hydrogen required for the DHDS process is generated in the hydrogen plant using
naphtha as a feed and fuel for burning. The steam reforming reaction of naphtha is
high temperature reaction.
PROCESS
Traces of H2S and mercaptans present in straight and cracked LPG are removed by
oxidizing then into odourless disulfide.
5. CRN MEROX
MAJOR EQUIPMENT
Reactors, caustic settler, sand filters
PROCESS
Cracked naphtha from FCCU mixed with air and routed to a reactor where MEROX
catalyst impregnated on charcoal be removes the foul smelling mercaptans by
converting them to odourless disulfides.
6. ATF MEROX:
MAJOR EQUIPMENT
Coalescer, reactor, water washer, caustic settler
PROCESS
Kerosene along with air is routed to the merox reactor where mercaptans are
converted to disulfides. Entrained caustic is separated out and moisture, extraneous
matter are removed in filters. This helps in manufacture of ATF.
The feed to this unit is a blend of Straight run and cracked gas oil from storages and
refineries in order to produce low sulphur content diesel oil. This unit consists of four
major sections:
∑ DHDS reaction section
∑ Amine absorption section
∑ Stripping section
∑ Naphtha stabilizing section
DHDS reaction section is a hydro treating process, which mainly consists of two
kinds of reactions:
∑ Refining reaction
∑ Hydrogenation
1. Refining reactions.
a. Desulphurisation
Mercaptans, sulphides, disulphides easily react leading to corresponding saturated
or aromatic compounds sulphur combined into cycle of aromatic structures like
thiophene is more difficult to eliminate. This reactions lead to H2S formation and
H2 consumption.
b. Denitrification.
The Denitrification reaction rate is lower than desulphurisation. It occurs in
heterocyclic compounds having aromatic structure. These leads to NH3 formation
and H2 consumption.
2. Hydrogenation reactions
These reactions affect diolefins , olefins and aromatics are exothermic. Diolefins and
olefins converted to saturated compounds. Hydrogenation rate of aromatics are
limited.
PARAMETERS
1. Temperature
Hydro treatment leads to increase in temperature and eventually lead to increase in
coke deposit which should be controlled. Thus temperature is maintained.
2. Space velocity
Lower the space velocity then higher is the reaction rates. As catalyst quantity is
constant space velocity charged by flow rate.
4. Feed quantity
It should be a constant. Severity can be with increase with high feed impurities.
Catalyst can absorb silicon, arsenic, metals etc which will affect compounds activity
of catalyst is drastically reduced.
1. STRIPPING
The liquid hydrocarbon phase of the cold separator is the stripper feed. First it is
preheated by the heat exchanger to reach the required stripper inlet temperature. Light
ends and H2S gather at the top of the stripper. Inhibitor is injected in the stripper
overhead line. The stripper outlet compressing three phases is separated in the stripper
reflux drum. The vapour feed to the low pressure(LP) amine absorber and vapour
generated from flashing of rich amine from HP amine absorber is washed by lean
solution to remove H2S. Later the vapour from this section is sent to the LP absorber
drum.
The decanted water from the stripper reflex drum is sent under boot level control to
the washing surge drum. The hydrogen liquid phase is split into reflux which is
returned to the stripper. The stripper feed is fed to the top of the naphtha stabilizer.
This stabilizer is reboiled.
A part of the stripper bottom is sent to reboil the stabilizer bottom and later mixed
with the original stream. Final cooling is achieved in the hydro treated diesel cooler.
The free water contained in the product is removed and routed to the washing water
drum.
2. CATALYST REGENERATION
During catalyst regeneration a mixture of nitrogen and oxygen is circulated by the
recycle compressor through the reaction section. The reactor effluent is neutralised by
the injection of ammonia before being cooled. Caustic soda is also pimped by the
washing water pump into the mixture to control the salt deposit. The spent caustic
soda is sent for recycling. The make up oxygen in the system is made by plant air
through the make up compressor.
Reactions:
∑ Elimination of Sulphur
∑ Elimination of nitrogen and oxygen
∑ Elimination of metals
∑ Saturation of olefins and diolefins
PLANT CAPACITIES
DHDS
Unit design capacity : 2.43MMTPA
Unit actual capacity : 2.43MMTPA
LPG MEROX
Design capacity: 35.9 m3/hr LPG
CRN MEROX
Design capacity: 86.8 m3/hr
ATF MEROX
Design capacity: 39.28 m3/hr
PRODUCTS
Hydro treated diesel, Stabilized Naphtha, Rich Amine and fuel gas from LP absorber,
sour water, Desulphurised diesel.
MS BLOCK
The main objective of MS block is to hydro treat straight run naphtha and heavy run naphtha
from CDUs and even from VBUs and removal of sulphur , nitrogen and other impurities from
the feed. Each unit of MS block has targeted qualities of octane number, olefins content,
aromatics content, parrafins content which is blended in the MS pool.
NHT
3.23 (9.7) {404}
NSU
OFFGAS 0.91(2.7){113} 42
2.33(6.98){291}
90 REGULAR
MS
7.76 (23.2) {970}
263
PRIME G+ GAS TO SRU INT 66
FCC
SHU NSU
FCC NAPHTHA 87
688(2064){86000}
42
Feed surge
drum Cold sep
Heater
Make-up Hydrogen +
Recycle gas
Stripper Naphtha
Splitter
10
Process
The sulphur present in the straight run naphtha is removed in the presence of hydrogen and
catalyst in the reactor maintained at desired temperature high pressure .Hydrogen sulphide
generated in the process is removed by stripping. Sweet naphtha splits into light naphtha(
feed to isom) and heavy naphtha(feed to CCR ) in splitter.
2. Reactor
Naphtha from the pumps is combined with hydrogen rich recycled gas from the
recycled gas compressor.
The combined feed is preheated by reactor stream by a set of heat exchangers. Then
it is further heated in a heater to the required temperature for the activation of the
catalyst. Then it is send to the NHT reactor. The NHT reactor removes sulphur,
nitrogen and other contaminants from the feed with the help of down flow catalyst
bed.
The catalyst used are aluminium and compounds of Ni and Mo. Reactor effluent
passes through the product condenser to condense naphtha vapours to low
temperature to recover naphtha and then enters the separator.
The separator is provided with water wash to wash off the salts and then separated
into 3 phases that include liquid naphtha , sour water and hydrogen recycle gas .
The hydrocarbon liquid from the separator is routed to stripping section to stripper
feed bottom exchangers where it is preheated. The sour water is send to sour water
stripper. The hydrogen recycle gas is recycled by a recycle compressor to combine
feed exchanger.
3. Stripping section
The hydrocarbon liquid from the separator is reboiled in a reboiler using VHP steam.
It is then sent to the stripper where H2S, water traces , light hydrocarbons , hydrogen
is stripped off at the bottom. The overhead vapour is sent to air cooler and then to the
stripper receiver where the vapour is sent to the splitter. The lighter hydrocarbon
collected from the stripper receiver is returned back to the stripper. Then any water
molecules condensed is routed to sour water stripper. The off gas from the splitter
receiver is removed under high pressure control to SRU.
4. Splitter section
The splitter splits hydro treated naphtha to light naphtha which is sent to the NIU unit
feed and heavy naphtha to CCR platform unit.
The splitter overhead vapours from top naphtha splitter is condensed by the
condensers and cooled. It is then sent to the splitter overhead receiver which is
pumped has light naphtha. A part of light naphtha is sent to NIU unit and other part is
pumped back to the splitter.
The splitter bottom is also divided into 2 streams. One part of the stream is sent to the
splitter reboiler, the other part is cooled in exchanges and the heavy naphtha
temperature is dropped to the atmospheric temperature and then sent to storage.
Plant capacities
Design capacity : 1.154 MMPTA
Feed rate : 215 m3/hr
NIU
Objective
Isomerisation of light hydro treated is carried out in series of two fixed bed reactors. Benzene
hydrogenation is highly exothermic , so separate bed reactor, installed upstream of two
isomerisation reactors. To limit temperature across hydrogenation reactor a part is cooled is
recycled to reactor.
The C5 or C6 isomerisation converts C5 /C6 parrafins to isoms and higher octane branched
arrangement over Pt catalyst in presence of hydrogen.
Reaction depends on equilibrium operations conducted . The low octane methyl pentanes and
unconverted n-hexanes are recycled back to the isomerisation reactor to achieve RON 88.5
minimum accuracy to estimate value.
Stabiliser column is used to remove light ends from reactor and remains effluent to
deisohexaniser (DIH)
DIH is used for removing and recycle low octane methyl pentanes and unconverted n-
hexanes . 2,3 dimethyl butanes , 2,2 dimethyl butanes and 2 methyl butanes are sent to MS
pool and bottom stream to LPG recovery.
The stabiliser reflux drum contains LPG, hydrogen, chloride which is sent to LPG recovery
via caustic scrubber where chlorides are removed by neutralisation with caustic soda.
Equipment-
Hydrogenation reactor , isomerisation reactors, flash drum, stabiliser column, deisohexaniser,
hydrogen dryers. Naphtha dryers, LPG separator drum, Scrubber drum,H2 gas compressor.
C4 ISOMERIZATION
C5 AND C6 ISOMERIZATION
Process
The objective of isom unit is to process light naphtha from NHT to obtain high octane
number gasoline. Benzene content in light naphtha will reduced to cyclohexane in the
hydrogenation reactor and n-paraffinic HC present in light naphtha get converted into
isoparrafins by isomerisation reaction. LPG and fuel gas are the by products in the process.
Light isomerate and heavy isomerate are the products from the unit which are routed to
gasoline pool of the refinery.
Unit flow description process
1. Dryer section
The light naphtha is fed to the feed surge drum is pumped into the dryers in series.
Feed dryers protect the isomerisation catalyst from moisture air and water which
deactivates or poisonous to it.
Hydrogen from the CCR is taken to the knock out drum and then compressed and
cooled. Part of it is sent to FCC-NHT.
Dried hydrogen is mixed with dried naphtha and sent to benzene hydrogenation
reactor.
2. Hydrogenation section
Combined two phase fed is preheated in reactor and mixed with diluents recycle from
hydrogenation reactor and then heated by HP steam to reaction temperature.
Benzene is hydrogenated to cyclohexane which is highly exothermic reaction and
then sent to flash drums. A part of it free from benzene is sent to isomerisation
reactors.
Incase of high benzene content, the diluents is cooled to control isomerisation reaction
temperature. Diluents recycle should not exceed
30 oC for exothermicity in hydrogenation reactor.
3. Isomerisation reactor
Isomerisation reactor feed from flash drum is mixed with hydrogen and small amount
of chloriding agent in order to maintain chloride balance on isomerisation catalyst .
the first stage isomerisation reactor converts C5 into methyl butanes which is then
cooled and set to second stage isomerisation reactor. In the second stage reactor C6
are converted to methyl pentanes which are further converted to di methyl butanes
and enters the stabiliser .
4. Stabilizer section
C1 to C4 hydrocarbons are removed from the top of the column. LPG , hydrogen, HCl
are stripped off to LPG recovery section via caustic scrubber. The bottom is sent to
deisohexaniser column via chloride bed where the chloride is removed.
5. Deisohexaniser
The feed from the DIH ump is pre heated and fractionated into 3 columns. The top
part is the light isomerate which is stabilised in the MS pool while the bottom is the
heavy isomerate which consists of 7 , C6 and naphthenes which is sent to LPG
recovery section for lean oil makeup.
The low octane methyl pentanes and n-hexanes are recycled back to the reactors.
6. Scrubber section
It is caustic treated and water washed before being release to LPG recovery section.
The off gas enters bottom of the caustic scrubber. The gas leaving caustic wash
section is washed with water to top pa section to remove entrained caustic and then to
LPG recovery section.
8. Dryers regeneration
The naphtha feed and hydrogen scrubber off gas are sent to respective dryers in series.
Feed H2 scrubber of gas dryers are regenerated to vaporised deisohexaniser distilled.
Plant capacities
Design capacity : 0.229 MMPTA
Feed rate : 42 m3/hr
CCR
Equipment
CCR reactor, Stabiliser, De ethaniser, Charge heater, inter heaters, cyclemax
regeneration section.
The objective of CCR unit is to process straight run gasoline to obtain high octane
number gasoline.
Process.
Naphthenic and paraffinic HC present in heavy naphtha get converted into aromatics
by catalytic reforming reactions in platformer at desired temperature and low pressure
in presence of platforming catalyst. Hydrogen and LPG are by products in this
process. Stabilized reformate is routed for blending of motor spirit. Catalyst
deactivates in the reaction due to coke formation and the same can be regenerated
continuously in CCR cycle max regeneration section and reused.
CCR Platforming
Objective
n-parrafins and iso parrafins are converted into cyclo pentanes and then into
cyclohexane and thus aromatics needed for MS pool.
More amount of naphthenes and less amount of parrafins are needed for production
of aromatics.
In reactor aromatics pass unchanged but naphthenes get cconverted to aromatics .
main carbon used are C6-C7. Rich naphtha feed is used from NHT.
Hydrogen rich gas from DHDS ia imported to start CCR platforming.
Unit flow process description
1. Feed section
Heavy naphtha from NHT bottom splitter is preheated by reactor effluent and
treated with sulphur injection, perchloroethylene injection and cold condensate
injection.
Chloride needed to maintain acidic sites for catalyst for isomerisation reactions to
occur and water to distribute chlorides throughout catalyst. The reactor effluent
moves in one direction while cold stream moves in opposite direction in heat
exchanger thus leading to heat transfer in feed .the hydrogen rich gas is heated up
to maintain hydrogen/hydrocarbon ratio for catalyst.
2. Reactor
Catalyst stability should be maintained. Steam generation from the flue gases in
heaters to HP and MP steam. It consist of four reactors :
a. Interheater no 1
b. Interheater no 2
c. Interheater no 3
d. Charge heater
Effluent from each reactor stage is heated and enters the next
reactor to maintain temperature . hydrogen gas is stacked back
and sent for recycle. Gas stream hydrocarbon is purged and
spent catalyst is sent for regeneration of CCR section.
The cold effluent from the reactors is sent to the separators.
3. Separator
The cold effluent is separated as hydrocarbon stream and hydrogen rich gas.
In the hydrogen rich gas part of it is sent as recycle to reactor and CCR
regeneration section, while remaining of the gas is cooled off and sent to
recontacting section. The hydrocarbon stream from top is sent to recontacting and
fractionation.
4. Recontacting section
The hydrogen C1,C2,C3,C4,C5 from the separator is sent to the recontacting
section. It enters the first stage reactor where it is cooled and the gas coming from
the first stage discharge is sent to second stage reactor where is again cooled and
sent to second stage discharge. The liquid from the first and second stage
discharge and the liquid hydrocarbon from separator is sent to the stabilizer.
The off gas coming out of second stage discharge is routed to remove chlorine and
the sent to LPG recovery section by adding propane to chiller and above product.
5. Stabilizer
The product is preheated and then sent to stabilizer column where overhead gas is
recycled to first stage suction drum , overhead liquid in which some part is sent
back as reflux and other part is sent to de ethaniser and then to chloride unit to
recover stabilised LPG as bottom product and while the bottom rich reformate to
sent to MS pool.
The catalyst used is chlorided Al base . the reformates consists from C5 .
CCR cyclemax
It consists of catalyst regeneration and catalyst circulation.
1. Catalyst regeneration
It basically includes :
a. Coke burning
b. Oxychlorination
c. Drying in regeneration tower
d. Reduction zone
2. Catalyst circulation
The catalyst is transformed from platforming reactor to regeneration reactor.
Spent catalyst flows from bottom of last reactor to catalyst collector.
Circulators N2 from lift gas blower engages catalyst lifts to disengaging
hopper .in hoper fine removal blower separates the additional fines and
nitrogen from catalyst from the top gas. Fines are collected in the dust
collector and nitrogen circulates back.
Whole catalyst drops from regeneration tower by gravity to nitrogen seal drum
and then to lock hopper. Then the hydrogen rich gas from recontact engages
catalyst and lifts it through catalyst lift line in regeneration zone to top of first
reactor and then catalyst collector.
The spent catalyst is the catalyst that leaves reactor purged to remove
hydrocarbon . Catalyst environment is changed from hydrogen to nitrogen
and done during lift operation of catalyst from bottom of reactor to top of
regeneration.
The regenerated catalyst environment is changed from nitrogen to hydrogen
from bottom of regenerator to top of reactor.
Regeneration tower catalyst passes through :
a. Burn
b. Reheat
c. Chlorination
d. Cooling zones
e. Drying
Two ways to operate regeneration :
1. Black burn
The burn and reheat zone contains oxygen while chlorination, drying,
cooling contains N2 . It is used when coked catalyst is in chlorination,
drying, cooling zone and restarting regeneration tower.
2. White burn
The burn and reheat contains oxygen while chlorination, drying,
cooling zone contains air. It is operated in regeneration tower.
Oxychlorination needs air and chlorine. It is used to redisperse metals
after burning and adds chlorine to catalyst. After black burn no coked
catalyst should go into zone and it be devoid of coke and then white
burn is started. It is important to start regeneration in white burn if
there is a risk of coked catalyst below burn zone. Otherwise high
temperature will lead to catalyst phase change and loosing activity.
Plant capacities
Design capacity : 0.769 MMPTA
Feed rate : 110 m3/hr
Equipment
Feed surge drum, Selective hydrogenation unit reactor, Splitter column, HDS reactor ,
Stabiliser, Amine absorber etc.
Objective
The objective of FCC NHT is to process FCC gasoline to obtain product streams(Light
gasoline and heavy hydrotreated gasoline ) with targeted qualities of octane number, sulphur
content, benzene content and olefins content. Prime G+ provides us to meet EURO-
3/EURO-4 specifications of gasoline wrt :
Diolefins : nil
Olefins : 18% Max
Sulphur : 50 ppm
Benzene : 1%
Schematic sketch of FCC NHT unit
21
Process
FCC CRN from FCCU unit is taken to the unit as hot feed. The CRN is taken to the feed
surge drum. CRN is then pumped to a series of heat exchangers and enters into selective
hydrogenation unit reactor. The purpose of the reactor is to convert diolefins to olefins and to
convert Mercaptans and lighter boiling sulphur compounds in the feed to higher boiling
sulphur species.
The outlet from the SRU reactor is routed to splitter where light naptha, heart cut naphtha and
heavy naphtha is separated. Light naphtha is directly routed to MS pool where as heart cut
naphtha which is rich in benzene content is routed to NHT unit.
The bottom heavy naphtha is passed again through series of heat exchangers and routed to
hydrodesulphurisation reactor (HDS reactor). Here the sulphur of the heavy naphtha is
reduced to allowable extent and the Desulphurised heavy gasoline (HCN) from the HDS
reactor is routed to naphtha stabiliser. The HCN is stripped off any dissolved H2S or lighter
compounds like C1.C2s and the stable HCN is routed to final refinery MS pool.
2. Splitter section
The splitter section consists of 52 trays. The feed enters at the 19th tray from the
bottom where it is fractionated to produce LCN and HCN. The splitter overhead is
condensed by air cooling in the splitter overhead air condenser. Vapour is separated
from the reflux liquid in splitter reflux drum. The splitter is again condensed and the
vapour is purged by split range control of pressurising hydrogen and venting the fuel
gas header. The reflux is then pumped to the pump by splitter reflux. The tray number
48 accumulator gives LCN which is cooled and stored. The splitter bottom is reboiled
by steam and heavy naphtha is sent to HDS unit. In tray number 36 benzene heart cut
is obtained which is cooled by air cooler and sent to storage.
4. Stabiliser section
The liquid is heated by the stabiliser feed bottom and sent to the stabiliser column. A
part of the liquid phase is cooled in the stabiliser overhead cooler and then sent to the
stabiliser reflux drum, while water phase is sent to the sour water treatment and in the
vapour phase the pressure is controlled by the gas flow. The other part of the liquid
phase coming from the stabiliser bottom is reboiled by VHP steam bailer which is
separated into 2 streams. Then the bottom product is treated and sent to MS storage
pool while the other part is cooled by stabiliser feed and heavy gasoline is obtained
which is recycled back.
Plant capacities
Design capacity : 0.893 MMPTA
Feed rate : 140 m3/hr
POWER AND UTILITIES
The main plants in utilities are :
1. Raw water systems
2. De mineralised plant
3. Power plants I &II
4. Captive power plant
5. Cryogenic nitrogen unit
6. Flare system
c. Drinking water
The drinking water consists of PSF and activated carbon filters. Filtered water is
chemically dosed and stored in drinking water sump. In sump NaOCl is added to
kill bacteria and free residual chlorine is maintained.
2. Demineralised plant
Equipment:
Sand filter, Strong acid cation , Weak base anion, Strong base anion, Degasser ,
Mixed bed.
Process:
Raw water is processed in ion exchangers to get demineralised water. The latest
technology used in VRCFP for demineralising water is reverse osmosis. Morpholine
is used to maintain pH of water.
7. Degassed tower
The water devoid of cations is passed to degasser air blower.
Plant capacities
Design capacity :
DM I : 75 M3/Hr
DM I : 120 M3/Hr
DM I : 180 M3/Hr
3. Power plants
Equipment :
Deaerator , Economiser , Bank tubes , Super heater , CO chamber.
Process :
DM water is processed to generate VHP , MP, HP steam in boilers.
Steam is also generated from the heat conservation of CO. Power plants are mainly
used for steam generation and power generation. Steam is also generated from the
flue gas from the gas turbine gas generators. PP I consists of WIL- 8 , BHPV, NCO ,
IBH-9, IBH-10 boiler . PP II consists of WIL–B , CO, BOP boilers. Water from DM
plant is sent to Deaerator where dissolved oxygen present is water is removed by HP
steam and then sent to boilers in PP I & PP II.
PP I generates HP, LP, MP steam for CDUs, Desalter, FD fans for boilers.
PP II generates HP, MP steam for deaerators , oil burners and heating systems.
Plant capacities :
PP I :
WIL 8 : 50 T/Hr
BHPV : 50 T/Hr
NEW CO : 40 T/Hr
PP II
CO : 60 T/Hr
Process:
Naphtha is used to run a gas turbine generator and thus produce power to cater the
demands of the whole refinery.
This also helps to generate steam using flue gas from GTGs .
It is used in cogeneration of steam and power leading to more energy efficient use of
fuel as compared to a conventional power plant. The fuel used is 4 naphtha tanks and
2 diesel tanks to supply for GTGs.
2. Generators
It is coupled with the gas turbine through gear box that reduces turbines speed.
The DC current enters the generator and then the automatic voltage regulator to
keep voltage constant. The various electrical instruments are 1 KV switch gear,
LT switch gear, 3 KV switch gear, uninterrupted power supply and CT switch
gear.
3. Heat recovery steam generator
Deaerator provides water for HRSGs. They are used to recover heat from turbine
exhaust gases. They is natural circulation single pressure horizontal duct fired
water tube boiler. The firing facility is also and steam production in HSRG is
done. The power from CPP is supplied to DM plant, feed water facilities and
Deaerator .
PLANT CAPACITIES
GTGs : 7.18 & 21.31 MW
HSRGs : 27 & 60 T/Hr
5. Flare system
Equipment:
Flare tip, Flare stack, Fluidic seal , Flame front generator, Water seal drum, Knock
out drum , Blow down pumps
Objective :
Flare facilities are provided in order to avoid releasing of in burnt hydrocarbons to the
atmosphere. Facilities exists for injecting steam to stack for smokeless flare for
refinery.
In view of additional hydrocarbon load subsequent to VRCFP commissioning,
additional flare facilities are provided in order to avoid releasing of un- burnt
hydrocarbons to the atmosphere.
This flare system also comprise of a separate AAG flare which is non smokeless type.
The liquid hydrogen discharges and separates to slop tank and knock out drums.
The existing system consists extremely toxic gases coming from VR & VREP I. CDU
I, CDU II, FCCU I. FCCU II, FCCU III & PRU total load is 698.5 tonnes/hr.
5. Flare stack
The top point is sent to the flare tip while the bottom is sent to flare system
bottom. Then it is sent to check O2 in gases. Continuous flue gas purge is provided
to keep pressure constant.
6. Flare seal
It is a gas lead pipe and it has an inverted cylinder over the lead pipe. The top of
the cylinder is closed while the bottom is opened. The lighter gases are collected
in the upper bend while heavier gases settle down in the lower bend.
Plant capacities
New flare : 698.5 MT/Hr
Old flare : 284.716 MT/Hr
VRCFP flare : 490.6 MT/Hr
Process :
1. Air suction and compressor
Air suction filter is compressed by main air centrifugal compressors to control the
pressure.
2. Air pre-cooling
The shell and tube heat exchangers cool the air by chilled water and the moisture
separator condenses water and separates moisture and sends the dry water to the
knock out drum. The cooling water which is cooled by waste N2, comes out of
cold box in the evaporation cooling tower. The chilled water is pumped into after
cooler and the return water is circulated back to evaporation cooling tower where
the losses are balanced.
3. Drying
Chilled air is passed to the adsorber where saturated moisture , CO2 are removed
by using aluminium and molecular sieves.
4. After filters
After elimination of aluminium and molecular sieve dust the degeneration steam
is mixed with waste air from cold box and heated. The hot gases passed through
the sieves to regenerate absorbents.
5. After cooling
Purified air is cooled down by return gases in heat exchangers. Cooled by GAN
the waste gases from condenser return to the turbines.
6. Distillation
In the distillation column O2 rich liquid and gaseous N2 is obtained from bottom
and top of the distillation column respectively. The rich liquid is throttled and then
vaporised and then condensed.
Plant capacities
Design capacity : 245 Nm3/Hr