TECHNICAL REPORT

ON

STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

2020/2021 SESSION (APRIL-SEPTEMBER)

UNDERTAKEN AT

PORT HARCOURT REFINING COMPANY LIMITED

A SUBSIDIARY OF NNPC

PREPARED BY
JAGGU DAVID ESLA
2016/1/59220EH

SUBMITTED TO

DEPARTMENT OF CHEMICAL ENGINEERING

SCHOOL OF INFRASTRUCTURE AND PROCESS ENGINEERING
TECHNOLOGY,

FEDERAL UNIVERSITY OF TECHNOLOGY MINNA, NIGER STATE,

NIGERIA.

IN PARTIAL FULFILMENT OF REQUIREMENTS FOR THE AWARD

OF BACHELOR OF ENGINEERING (B.ENG.) DEGREE IN
CHEMICAL ENGINEERING.
OCTOBER 2021.

i
CERTIFICATION

This is to certify that this work was undertaken by JAGGU DAVID ESLA with
Matriculation Number 2016/1/59220EH at Port Harcourt Refining Company Limited
(PHRC), Alesa-Eleme P. O. Box 585, Port Harcourt, Nigeria. The report was prepared
and presented to the Department of Chemical Engineering, Federal University of
Technology, Minna, Niger State, Nigeria during the 2020/2021 Students Industrial
Work Experience Scheme (SIWES).

ii
DEDICATION
I whole heartedly dedicate this report first and foremost to the Almighty God for his
mercy, favour, faithfulness and love upon my life. His mercies indeed encompass
everything. Special thanks to my parents (Mr. and Mrs. Yohanna Jaggu) for their
unending love, support, encouragement and guidance during my SIWES program and
also to those who seek the advancement of knowledge.

To God alone be all the glory.

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ACKNOWLEDGEMENTS
A lot of people contributed eminently to the success of my industrial program. Firstly,
with a deep sense of appreciation, respect and gratitude, I say a very big thank you to Dr
Bafred Audu Enjugu for his immeasurable support, encouragement, guidance and
unending motivation from the point of securing my internship placement to the end of
my training and beyond. Secondly, special thanks to Engr. Efifia Chu (Manager PPU,
PHRC) for his intellectual support and guidance towards the success of my training. I
thank the human resources management and staff of Port Harcourt Refining Company
Limited for the opportunity given to me to undertake my Industrial training in their
company. My special gratitude also goes to my supervisors while at PHRC; Engr.
Wakama, Engr. Olayinka, Engr. Agba, Mr Naewi, Mr Jiji Benson, Mr David, Mr
Mukhtar, Mr Enyo, Mr Okon, Mr Monday and Mr Chikwado for their priceless
assistance, encouragement, co-operation and equipping me with the necessary
information and knowledge towards understanding basic engineering principles as well
as their constructive corrections, useful advice, support and training during my stay.
Lastly, I wish to thank my friends and colleagues Miracle Milestone and Ephraim
Akolo Jonah for their endless contribution to the success to my training.

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ABSTRACT
This Students Industrial Work Experience Scheme (SIWES) report gives the experience
acquired during my six months industrial training undertaken at Port Harcourt Refining
Company Ltd located at Alesa-Eleme, Rivers State. The Student Industrial Work
Experience Scheme (SIWES) is designed to enable undergraduate students of tertiary
institutions learn and acquire practical skills. The main objective of this scheme is to
acquire practical skills and experience first-hand on all the theoretical work they have
been taught in class.

This report summarizes my industrial training experiences at PHRC. The

technical skills and experience gained during my training period are given in detailed
explanation and justifies the relevance of the scheme in equipping students with needed
technical competence to thrive in the real world. My training was undertaken at the
Fuels Plant Ⅱ (Area 5) under production department, which comprises of process,
electrical and mechanical engineers. This report comprises of the background of
SIWES, its aims and objectives including the roles of the various organizations, the
history and background of PHRC and its structure, introduction to oil and gas processes,
process methodology and the experiences I gained.

During the training period, I was able to model and simulate the Crude Distillation Unit
(CDU) of the plant using Aspen Hysys (version 10). I also learnt about the refining
process from the dedicated, committed and well experienced refiners I worked with. My
experience greatly improved my basic engineering knowledge

I was able to gain a better appreciation of my discipline and relate theoretical

knowledge to industry practice. I also got to interact with professionals from different
disciplines; both PHRC staff and Maire Tecnimont staff; an Italian company that deals
in plant engineering in oil and gas, that was handling the rehabilitation of the refinery.

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My experience enhanced my constructive thinking and analysis, problem solving and
team work skills. Further included are the challenges encountered and the mitigations to
those challenges.

TABLE OF CONTENT

Contents
CERTIFICATION………………………………………………………………………
………...ⅱ

DEDICATION....................................................................................................................iii

ACKNOWLEDEMENT…………………………………………………………………
…….…ⅳ

ABSTRACT........................................................................................................................v

1 INTRODUCTION........................................................................................................1

1.1 BRIEF OVERVIEW OF SIWES..............................................................................1

1.2 OBJECTIVES OF SIWES.......................................................................................1

1.2.1 ROLES OF FEDERAL GOVERNMENT..........................................................2

1.2.2 ROLE OF ITF..................................................................................................2

1.2.3 ROLE OF EMPLOYERS..................................................................................2

1.2.4 ROLE OF UNIVERSITIES...............................................................................2

1.2.5 ROLE OF STUDENTS.....................................................................................2

1.3 BACKGROUND OF ESTABLISHMENT................................................................3

1.3.1 NIGERIAN NATIONAL PETROLEUM CORPORATION (NNPC)...................3

1.3.2 PORT HARCOURT REFINING COMPANY LIMITED (PHRC).......................5

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 1.3.3 ABOUT PHRC................................................................................................5

1.3.4 HISTORICAL BACKGROUND.......................................................................5

1.3.5 PRODUCTS OF PHRC....................................................................................7

1.3.6 PRODUCTS EVACUATION...........................................................................7

1.3.7 VARIOUS DEPARTMENTS AND THEIR FUNCTIONS IN

REFINERY.................................................................................................................8

1.3.8 FOCUS ON SAFETY.......................................................................................9

1.3.9 ENVIRONMENT..........................................................................................10

1.3.10 COMMUNITY..............................................................................................10

1.3.11 BUSSINESS OPPORTUNITIES.....................................................................11

1.3.12 PHRC MISSION & VISION STATEMENT....................................................11

1.3.13 GENERAL RULES, REGULATIONS AND PROCEDURES AT THE

REFINERY....................................................................................................................
12

SAFETY EQUIPMENT AND PRECAUTIONS............................................................13

2 LITERATURE REVIEW............................................................................................18

2.1 NEW PORT HARCOURT REFINERY SIMPLIFIED PROCESS (NPHR)...............18

2.1.1 ATMOSPHERIC CRUDE DISTILLATION UNIT...........................................18

2.1.2 VACUUM DISTILLATION UNIT.................................................................20

2.1.3 NAPHTHA HYDRO-TREATING UNIT.........................................................20

2.1.4 CATALYTIC REFORMING UNIT.................................................................20

2.1.5 KEROSENE HYDRO-TREATING UNIT.......................................................21

2.1.6 FLUID CATALYTIC CRACKING UNIT.......................................................21

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 2.1.7 DIMERSOL UNIT.........................................................................................22

2.1.8 BUTAMER UNIT..........................................................................................22

2.1.9 HF ALKYLATION UNIT..............................................................................22

2.1.10 OLD PORT HARCOURT REFINERY (OPHR) PLANT..................................23

2.1.11 REFINERY’S PRODUCTS, UNITS AND USES.............................................23

3 METHODOLOGY......................................................................................................25

3.1 UNITS THAT MAKE UP REFINING FUELS PLANT Ⅱ.......................................25

3.2 THE REFINING PROCESS..................................................................................26

3.2.1 CRUDE DISTILLATION UNIT.....................................................................26

3.2.2 CATALYTIC REFORMING UNIT (CRU)......................................................45

3.2.3 RECYCLE GAS TREATING SYSTEM (ADIP UNIT 17)................................49

3.2.4 LIQUEFIED PETROLEUM GAS (LPG) UNIT...............................................52

3.2.5 FLARE SYSTEM UNIT.................................................................................56

3.2.6 RAW WATER SYSTEM UNIT......................................................................57

3.2.7 TREATED WATER SYSTEM UNIT.............................................................57

3.2.8 STEAM SYSTEM UNIT................................................................................58

3.2.9 COOLING WATER SYSTEM UNIT..............................................................60

3.2.10 FUEL GAS SYSTEM UNIT...........................................................................64

3.2.11 PLANT & INSTRUMENT AIR UNIT.............................................................64

EXPERIENCE GAINED....................................................................................................67

MODELLING OF CRUDE DISTILLATION UNIT USING ASPEN HYSYS...................1

CONCLUSION AND RECOMMENDATION.......................................................................3

CONCLUSION................................................................................................................3

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 RECOMMENDATION.....................................................................................................3

LIST OF TABLES
Table 1: Plant units, products and uses 20-21
Table 2: Fuels plant Ⅱ units 22
Table 3: Information on Distillation Column, products and strippers 36-37
Table 4: Distillation Column products and flowrates 38
Table 5: Chemicals used in CDU 42
Table 6: Chemicals used in CRU 49
Table 7: Recycle gas composition 50
Table 8: LPG Composition 51

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LIST OF FIGURES

Figure 1: NNPC board organogram 4

Figure 1b: Fire triangle 9
Figure 2: ORANOGRAM of PHRC 10
Figure 3.1: Safety hand gloves 11
Figure 3.2: Safety goggles 11
Figure 3.3: Safety boot 11
Figure 3.4: Helmet 12
Figure 3b: The CDU. 23
Figure 4: Major parts of a centrifugal pump 25
Figure 5: Parts of the centrifugal pump 26
Figure 6: Reciprocating pump 27
Figure 7: Parts of a valve 28
Figure 8: Parts of a Shell and Tube Heat Exchanger 30
Figure 9: Schematic of Desalter 31
Figure 10: Sections of a fired heater 32
Figure 11: Fractionating column, reboiler and condenser 34
Figure 12: Bubble cap tray 35
Figure 13: Fixing of trays in the column 35
Figure 14: Image of Induced Cooling Tower 59
Figure 15: Schematic of how the cooling tower works 60

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Figure 16: Parts and arrangement of the Induced and Forced Draft design of the
cooling tower 61
Figure 17: Sample modelling of crude preheat train and crude fractional
distillation on main flowsheet of Aspen Hysys version 10 65
Figure 18: Sample modelling of the fractional distillation column in the column
environment using Aspen Hysys version 10 65

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 CHAPTER ONE
1 INTRODUCTION
1.1 BRIEF OVERVIEW OF SIWES
SIWES was established by ITF in 1973 to solve the problems of lack of adequate
practical skills preparatory for employment in industries by Nigerian graduates of
tertiary institutions. The scheme exposes students to industry-based skills necessary for
a smooth transition from the classroom to the world of work. It affords students of
tertiary institutions the opportunity of being familiar and exposed to the needed
experience in handling machinery and equipment which are usually not available in the
educational institutions. Participation in SIWES has become a necessary pre-condition
for the award of Diploma and Degree certificates in specific disciplines in most
institutions of higher learning in the country, in accordance with the education policy of
government. The operators are the ITF, the coordinating agencies (NUC, NCCE, and
NBTE), employers of labour and the institution. The funding is handled by the Federal
Government of Nigeria. The beneficiaries are the undergraduate students of the
following include: Agriculture, Engineering, Technology, Environmental, Science,
Education, Medical Science and Pure and Applied Sciences. The duration of the
program is four months for Polytechnics and Colleges of Education, and Six months for
the universities.[1]

1.2 OBJECTIVES OF SIWES

The objectives of SIWES are:

1. To provide an avenue for students in Nigerian universities to acquire industrial

skills and experience during their course of study.
2. To prepare students for the work situation they are likely to meet after
graduation.
3. To expose the students to work methods and techniques in handling
equipment and machinery that may not be available in their universities.
4. To allow the transition phase from school to the world of working
environment easier and facilitate students’ contact for later job placements.

65
 5. To provide students with an opportunity to apply their theoretical knowledge
in real work situation thereby bridging the gap between theory and practice.

1.2.1 ROLES OF FEDERAL GOVERNMENT

1. To provide adequate funds to the ITF through the Federal Ministry of Industry
for the scheme.
2. To make it mandatory for all ministries, companies and parastatals to offer
places to students in accordance with the provisions of Decree No. 47 of 1971 as
amended in 1990.
3. Formulate policies to guide the running of the scheme nationally.

1.2.2 ROLE OF ITF

1. Formulate policies and guidelines on SIWES for distribution to all the SIWES
participating bodies.
2. Organise orientation programmes for students prior to attachment.
3. Provide information on companies for attachment and assist in industrial
placement of students.

1.2.3 ROLE OF EMPLOYERS

1. Accept students and assign them to relevant on-the-job training;
2. Provide tailor-made training programmes for the students.
3. Attach experienced staff to students for effective training and supervision.

1.2.4 ROLE OF UNIVERSITIES

1. Organize orientation programmes for students to prepare them for industrial
training. ITF representative may be invited to give a talk to the students during
the orientation programme.
2. Prepare and submit master and placement lists to the respective coordinating
agency and ITF.
3. Establish SIWES coordinating units and appoint department/faculty SIWES
coordinators within the institutions.

2
1.2.5 ROLE OF STUDENTS
1. Comply with the employer’s rules and regulations.
2. Keep proper records of training activities and other assignments in the logbook.
3. Arrange their own accommodation during the period of attachment

4. Submit Log Books, Reports and other documents related to SIWES as required
by their institution at the end of the training period;

1.3 BACKGROUND OF ESTABLISHMENT

1.3.1 NIGERIAN NATIONAL PETROLEUM CORPORATION

(NNPC)
The Nigerian National Petroleum Corporation (NNPC) is the state oil corporation
which was established on April 1, 1977. In addition to its exploration activities, the
corporation was given powers and operational interests in refining, petrochemicals and
products transportation as well as marketing. Between 1978 and 1989, NNPC
constructed refineries in Warri, Kaduna and Port Harcourt and took over the 35,000-
barrel Shell Refinery established in Port Harcourt in 1965.

In 1988, the NNPC was commercialised into 12 strategic business units, covering the
entire spectrum of oil industry operations: exploration and production, gas development,
refining, distribution, petrochemicals, engineering, and commercial investments.
Currently, the subsidiary companies include:

Nigerian Petroleum Development Company (NPDC)

The Nigerian Gas Company (NGC)

The Products and Pipelines Marketing Company (PPMC)

Integrated Data Services Limited (IDSL)

National Engineering and Technical Company Limited (NETCO)

Hydrocarbon Services Nigeria Limited (HYSON)

3
Warri Refinery and Petrochemical Co. Limited (WRPC)

Kaduna Refinery and Petrochemical Co. Limited (KRPC)

Port Harcourt Refining Co. Limited (PHRC)

NNPC Retail

Duke Oil

In addition to these subsidiaries, the industry is also regulated by the Department of

Petroleum Resources (DPR), a department within the Ministry of Petroleum Resources.
The DPR ensures compliance with industry regulations; processes applications for
licenses, leases and permits, establishes and enforces environmental regulations. The
DPR, and NAPIMS, play a very crucial role in the day to day activities throughout the
industry

4
Figure 1: NNPC Board Organogram.

1.3.2 PORT HARCOURT REFINING COMPANY LIMITED

(PHRC)

1.3.3 ABOUT PHRC

The Port-Harcourt Refining Company Limited (PHRC) Is one of the three refineries
wholly owned by The Government of The Federal Republic of Nigeria and managed by
The Nigerian National Petroleum Corporation (NNPC) as one of its 11 subsidiary

5
companies. The refining complex is comprised of two refineries. The Old Port Harcourt
Refinery (OPHR) with a processing capacity of 60,000BPSD and the New Port
Harcourt Refinery with processing capacity of 150,000BPSD. The combined total
refining capacity of the complex is 210,000BPSD. This constitutes about 47% of the
total NNPC Crude Oil Refining Capacity in Nigeria.

The company produces Liquefied Petroleum Gas (LPG), Premium Motor Spirit (Petrol
or Gasoline), Domestic Purpose Kerosene (DPK), Automotive Gas Oil (AGO or
Diesel), and Fuel Oils. Its facilities are located on the same site at Alesa-Eleme, some
25 kilometres East of Port Harcourt, the capital of Rivers state and occupies an area of
about 900 hectares.

1.3.4 HISTORICAL BACKGROUND

The Port-Harcourt Refining Company Limited started with the construction and
commissioning of a 35,000 BPSD hydro-skimming refinery in 1965 by a consortium of
British Petroleum and Shell. It was then known as BP/Shell Petroleum Refining
Company of Nigeria Limited. In 1972, the refinery was expanded to 60,000BPSD
capacity and renamed the Nigerian Petroleum Refining Company Limited (NPRC) after
acquisition of 50% shares of the company by the Federal and Regional Governments of
Nigeria. The joint venture partners of BP/Shell and Regional (now states) governments
finally relinquished their shares to the Federal Government, resulting in the voluntary
liquidation of NPRC in January 1986 and take-over of the management by NNPC. Prior
to this, NNPC had, in 1985, commenced construction of a new 150,000BPSD refinery,
which achieved mechanical completion in 1988. In 1988, the old and the new refineries
were brought under a single management by NNPC under the name Port Harcourt
refining company (PHRC) Limited. The new refinery was commissioned in 1989.

It has five (5) process areas Area 1-5. The new refinery is made up of Area 1-4 while
the old refinery is Area 5.

Area 1 is made up of the Crude Distillation Unit (CDU), where kerosene and
Automotive Gas Oil (AGO) are produced as finished products. Other intermediate
products form CDU are Straight- Run Naphtha (SRN), Straight Run Gasoline (SRG)
6
used for PMS bend, Liquefied Petroleum Gas (LPG) and Atmospheric Residue (AR).
Vacuum Distillation Unit (VDU) where AR (CDU bottoms) are further processed under
vacuum, or significantly less than atmospheric pressure to produce high -value products
without cracking like Vacuum Gas Oil (VGO), FCCU feedstock and light as gas oil.

Area 2 is made up of Naphtha Hydro-treating Unit (NHU), where naphtha is hydro-

desulphurisation; the Catalytic Reforming Unit (CRU), responsible for upgrading
naphtha to reformate which has a higher-octane value for PMS blend; the Kerosene
Hydro-treating Unit (KHU) where kerosene is treated to make it acceptable for aviation
use: Area 2 also has the Continuous Catalyst Regeneration Unit (CCR), which
constantly reactivates the deactivated catalyst from the reformer. Other units in Area 2
includes, the Hydrogen Purification, Fuel Gas Vaporizer, Sour Water Treatment and
Caustic Treatment Units.

Area 3 is made up of Fluid Catalytic Cracking Unit (FCCU), where Vacuum Gas Oil
(VGO) and heavy diesel oil (HDO) are cracked to obtain more valuable products, like
FCC gasoline used as PMS blend and Light Cycle are blend component for LPFO (Low
Pour Fuel Oil) and LPG (Liquefied Petroleum Gas). Other units in Area 3 includes Gas
Concentration, Gas Treatment and Mercaptan Oxidation Units.

Area 4 has three process units namely, Demersol, Butane Isomerisation and Alkylation
Units. The units are designed to produce high octane gasoline blend component.

Area 5, which is the old refinery, is made up of the Crude Distillation Unit (CDU); the
Platform Unit (CRU), the LPG Unit, as well as utilities section.

The refinery is self-sufficient in power and utilities generated from the Power Plant &

utilities. There are four (4) turbo-generators each with a capacity of 15MW of electricity

per hour and four (4) Boilers, capable of generating 120tons of steam per hour each.

The section also generates cooling/service water, plant/instrument air and nitrogen.

The refinery has a pool of maintenance personnel that take care of routine, programmed

and emergency repairs of equipment.There is also the Supply Chain Management

7
Department that oversees the procurement and storage of needed spare parts and

chemicals.

1.3.5 PRODUCTS OF PHRC

PHRC produces the following products: Liquefied Petroleum Gas (LPG), Premium

Motor Spirit (PMS), Kerosene (aviation and domestic), Automotive Gas Oil (AGO -

diesel), Low Pour Fuel Oil (LPFO) and High Pour Fuel Oil (HPFO). PHRC produces

UNLEADED gasoline that meets international standard. The PHRC also has in-house

firefighting capabilities.

1.3.6 VARIOUS DEPARTMENTS AND THEIR FUNCTIONS IN

REFINERY
The various departments and their functions in the Port Harcourt Refining company
include:

Health Safety and Environment (HSE): Safety department ensures that processed fluids
stay contained and that work procedures are designed and executed in ways that hurt no
one, while Environmental ensure compliance with regulations and laws for protecting
the environment.

Production: The department involves operations like distillation, extraction, cracking,

reforming, desalting etc of crudes.

Engineering Technical Servicing Department: This department maintains the computer

and network systems the refinery depends on.

Power plant utilities: This department provides power, steam, water etc for process.

Maintenance: This department is responsible for up keeping and repairing of equipment.

Stock control management Department: This department buy things that every
department needs.

8
Planning and budget monitoring: This department is responsible for planning the
company’s financial activities.

Total Quality Management: This department ensures that all products made in the
refinery are of acceptable standards. They also ensure that good quality polices are
made.

Accounts: The department is responsible for recording and reporting the cash flow
transactions of the company.

Human Resources: This department is saddled with the responsibility of recruiting,

screening, interviewing and placing workers in the refinery. They also handle employee
relations, payroll and training.

Administration: They work to ensure an effective performance of all departments in the

company. They also manage office stock, preparing regular reports and organizing the
company’s records.

Production programming and quality Control: It is made up of two sections; production

programming section and quality control section. The production programming
sections are in charge of the plant control room. They oversee the activities in the plant
from the control room using their computers. The quality control section analyses the
samples of product and wastewater effluent to ensure they are of acceptable standard.

1.3.7 FOCUS ON SAFETY

The health and safety of employees, contractors, subcontractors, clients and the
community are a top priority for the Refinery management. Safety is the responsibility
of all employees, contractors, subcontractors and visitors. Managers and supervisors
provide strong leadership in ensuring that all protocols are strictly adhered to in the
course of operating plant equipment. This extends to identifying and moving existing
and potential work hazards, providing and maintaining safety and health requirements
on speed limit, protective clothing, housekeeping, vehicles’ spark arrestors, etc.

Amongst its several responsibilities, the Safety department also enforces and penalizes
any safety breaches. Safety training is also anchored in liaison with the Training
department on the need to equip personnel to respond appropriately to rare emergency

9
situations. Mustering points are well marked out and a plant-wide public address system
is available to advice on any of such situations. Regular fire drills are also carried out at
various locations.

The department is also provided with a fire Service Section with enviable facilities.

Figure 1b: Fire triangle.

The refinery plant clinic meets the standard of its equivalent anywhere in the world.
This is open also to contractors, subcontractors or visitors for first aid and minor injury
treatments sustained during course of work at the refinery.

The refinery conducts annual safety enlightenment week to take stock of achievements
and map out future areas of emphasis. Safety is taken so seriously that it forms part of
the daily work routine and gets great attention in our annual strategic plan.

1.3.8 PHRC MISSION & VISION STATEMENT

MISSION: The Port Harcourt Refining Company is in business to provide efficient

high-quality petroleum refining services at minimum cost to local and foreign customers
and to develop and exploit other related business opportunities.

10
VISION: The Port Harcourt Refining Company will be a world class refining company
driven by shared commitment to customer satisfaction, employee empowerment,
professionalism and continuous improvement.

Fig 2: ORANOGRAM OF PHRC.

1.3.9 GENERAL RULES, REGULATIONS AND PROCEDURES

AT THE REFINERY
These instructions are designed to assist you in choosing a safe and environmentally
sound course of action in situations where no special rule applies and where personal
judgment becomes a factor. Heeding the suggestions, hints, and tips contained in these
instructions will help to prevent injury to you and your fellow workers or an adverse
impact on the environment.

11
 SAFETY EQUIPMENT AND PRECAUTIONS.
A safety precaution is a measure that one takes to prevent any injury or harm to either
oneself or anyone or thing in your surroundings. To avoid casualties of any kind in the
workshop or on the site, all students must admit safety first during the course of the
SWEP attachment. These safety precautions include:

i. wearing a fitted overall and helmet in the workshop is compulsory.

ii. wearing of safety boot or any protective shoe.
iii. do not put on any magnetic ornament.
iv. before commencing any welding operations, make sure that an appropriate fire
extinguisher is readily accessible.
v. proper concentration on the practical work.
vi. not wearing neck tie near a revolving machine.
vii. wearing a protective goggle when working with fine particles or face shield
during welding operations.
viii. staying away from unprotected electricity wires.
ix. reading and following instructions carefully before operating any machine.

Some safety equipment includes:

Figure 3.1: Safety Hand Gloves.

12
Figure 3.2: Safety Goggles.

Figure 3.3: Safety Boot.

Figure 3.4: Helmet.

 Correct unsafe conditions yourself if you see tools, materials etc on platforms or
walkways, remove them to eliminate tripping hazards. Correct any slipping hazards that
you can, put oil dry, sand or salt on slippery surfaces. Stop any leaks creating health,
safety or environmental hazards and report incidents to your supervisor.

 Study your job from the safety angle. Think before you starting work. Look at the
possible consequences of your actions and prevent accidents from happening. Get all
necessary protective equipment before you start work. Ensure chemicals are properly
stored and handled. Consult the MSDS and procedure manual for proper protective
clothing or equipment, or consult your supervisor. Be alert for potential hydrocarbon or
chemical leaks which may arise.

 Mental distractions spell danger when the mind is in one place and body in another. If
you have a personal situation persistently bothering you, tell your supervisor so he/she
can consider this before assigning your job.

 Report all hazards and near-misses immediately to your supervisor. PHRC wants to
provide safe and environmentally sound working conditions. You can assist by
reporting any unsafe conditions you observe. Near-miss accidents and environmental
13
incidents often reveal such conditions, tell your supervisor about them. Your actions
could prevent injury or damage to plant equipment or the environment.

 Inspect tools and equipment before using them. The prevention of serious injury or
loss of life may depend on the safe condition of the ladder, rope, tool, or other
equipment you are about to use. If you have any doubt about its safeness - DO NOT
USE IT - Have the equipment repaired.

 Stop unsafe work: You have the right and obligation to stop any work that is unsafe.

 Lift properly: To avoid serious back injury, bend your legs to get close to the object,
keep your back straight, get a firm grasp, and lift by straightening your legs. If the
object is too heavy for you, get someone to help you or use lifting equipment.

 Understand the chemical hazards: Read the Material Safety Data Sheets, also known
as MSDSs and chemical labels to understand the chemicals in the refinery. The MSDS’s
are available throughout the refinery. PHRC wants all employees to stay updated on this
information as their health depends on it. Ensure chemicals are handled and stored
properly to avoid a release to the environment.

 Handle materials with care: By keeping your hands away from pinch points and avoid
placing any part of your body where it could be caught between moving objects. When
a job requires that you exert force on an object, be in a comfortable, non-awkward
position to avoid strains and sprains. Use safety shoes to help prevent foot and toe
injuries and gloves to help prevent hand and finger injuries.

 Move about the plant safely and do not take shortcuts: Use regular walkways,
passageways, stairs and ladders. Watch where you walk, especially when walking on
gravel and stone surfaces. Stay particularly attentive when you climb ladders and
stairways. Step, don’t jump, from one level to another. Safety harnesses are required fall
protection for some elevated work - get them from the Fisher Safety Store or talk to
your supervisor about how to obtain a safety harness.

 Good housekeeping/environment is essential to the refinery. It will result in fewer

accidents, minimize impact to the environment and will reduce the hazards. All oil spills

14
must be avoided. In the event of a spill a prompt clean-up will minimize slipping,
environmental impact and any hazards.

 Passages and walkways must be kept free of welding rods, tools, draped hoses,
extension cords and other objects which create stumbling hazards. Cleaning up the area
where you are working is part of the job. This is our refinery, if we don’t take care of it,
who will?

 Avoid breathing petroleum vapours: overexposure to petroleum vapours may produce

a form of intoxication or other serious health effects. If you find yourself exposed to
vapours or fumes get to fresh air at once. Report this immediately to your supervisor
because repeated exposure to certain chemicals may create long term health hazards. Do
not return unless the area has been tested or you’re wearing proper breathing protection.

 Asbestos awareness; the key is to avoid exposures. Asbestos may be found in older
material such as insulation, floor tile, ceiling tile, transit siding, etc. Unless positively
identified, assume all material contains Asbestos and do not disturb.

 Read the bulletin boards and watch the poster board. Safety and Environmental alerts
and lessons learned from incidents will be posted. Read them to learn more about
accident and environmental incident prevention.

 Be watchful for the safety of others especially visitors who may not be familiar with
the operations. They may require a refinery employee escort. If you see them in
locations where they are likely to be injured, tell them.

 Assess the potential of the emergency and follow directions as detailed in the refinery
emergency plan.

 When the refinery emergency alarms sound, you should immediately stop all work,
shut down all equipment and listen for instructions over the PA system. If you are
instructed to evacuate, you should proceed immediately to your designated assembly
area. Evacuate upwind of the release. Be sure you know and understand your
responsibilities. For more information talk to your supervisor.

15
 Rings, earrings & long hair have caused many serious injuries and amputations by
catching on or between moving equipment. Employees are cautioned not to wear
jewellery while working in the refinery. Secure long hair in a hat or tie back.

 When PPE is required: PHRC employees, contractors, visitors etc., will generally not
be required to wear PPE inside building or enclosed vehicles. PHRC employees,
contractors, visitors etc., will generally not be required to wear PPE inside the ‘green
zone’ on the attached map. This exception is intended to allow people to travel to/from
points in the ‘green zone’ without PPE. A pre-task risk assessment shall be conducted
for all jobs inside the ‘green zone’ to determine the appropriate PPE for the job. PPE is
not required when walking to/from and enclosed motor vehicle and a building outside
the ‘green zone’ provided the parking space is in close proximity.

CHAPTER TWO

2 LITERATURE REVIEW

2.1 NEW PORT HARCOURT REFINERY SIMPLIFIED PROCESS

(NPHR)

NPHR process units are classified into Areas 1-4. Area 1 consists of the Crude and the
Vacuum Distillation Units. These units fractionate the crude into primary products of
LPG, Naphtha, Kerosene, Diesel Oil and Residual Fuel Oil. To meet desired
specifications, some of these primary products are subjected to further processing in
secondary units, which employ various chemical reactions, to upgrade the quality of the
products and maximize their yields. In Area 2, the NHU and CRU improve the quality
of naphtha to reformate (high octane PMS blending component) while the KHU
transforms the raw Kerosene into quality aviation turbine fuel.

Area 3 represents the main commercial heart of any refinery where the FCCU converts
the otherwise low value bottoms of atmospheric distillation into additional volumes of

16
high-quality PMS component, LPG to Alkylate and Dimate (also PMS blending
components) respectively. The products are pooled into intermediate storage tanks at the
Refinery Products Tank Farm where various components are blended to meet desired
market specifications of the final products.

2.1.1 ATMOSPHERIC CRUDE DISTILLATION UNIT

Raw crude oil is pumped to the unit after settling and dewatering at the tank farm. It
passes through a heat exchanger train, the desalter (for removal of salt and sediments),
the pre-flash drum (for removal of light ends), and the main crude heater where it is
heated up then to the main fractionator column. This is also called the distillation tower
in which the distillation trays ensure thorough mixing and separation of liquids from
vapours. The vapours are removed from the top of the fractionator, condensed and sent
to the Saturated Gas Concentration Unit (SGCU) for further separation and production
of LPG or cooking gas.

The liquids are withdrawn from the side of the fractionator, based on the boiling point
ranges as products.

The liquid products are as follows:

Whole Naphtha

Straight Run Kerosene

Light Diesel Oil

Heavy Diesel Oil

Atmospheric Residue

These products are classified as either finished or semi-finished. The semi-finished

products are further subjected to secondary processing to obtain finished products. The
Whole Naphtha is stabilized by stripping it further of light components (methane,
ethane propane and butane), then split into Straight Run Gasoline (SRG). The SRG is

17
sent to intermediate products storage as one of the components to be blended to produce
Premium Motor Spirit (PMS). The SRN is sent to Naphtha Hydro-treating and Catalytic
Reforming Units (NHU/CRU) to produce reformate used as a component for PMS
blending. The reformate is of a much higher-octane number (a measure of PMS quality)
than the Straight Run Naphtha.

The Straight Run Kerosene, also known as Dual Purpose Kerosene (DPK) is used either
directly as Household Kerosene or as Aviation Fuel after further processing and
introduction of additives. For the production of Aviation Turbine Kerosene (jet – A1), a
part of the Straight Run Kerosene is sent to the kerosene Hydro-treating Unit (KHU) for
improvement of the smoke point, etc.

The Light Diesel Oil is a finished product and used directly as Automotive Gas Oil
(AGO) or Diesel. The heavy Diesel Oil (HDO) forms part of the feedstock for the Fluid
Catalytic Cracking Unit (FCCU) and is sent to storage. The last fraction is the
Atmospheric Residue (AR) and this is sent to the Vacuum Distillation Unit to obtain
feedstock for FCCU.

2.1.2 VACUUM DISTILLATION UNIT

The Atmospheric Residue is processed in the Vacuum Distillation Column under very
low pressure (vacuum) but at slightly higher operating temperature than in the CDU.
The products from this vacuum column are Light Vacuum Gas Oil (LVGO), Heavy
Vacuum Gas Oil HVGO) and Vacuum Residue (VR). The LVGO and HVGO are
combined to form a composite product – Vacuum Gas Oil (VGO), which is the main
feedstock for the FCCU. The bottom product of the vacuum column, Vacuum Residue
(VR) is sent to storage for blending into Fuel Oil.

2.1.3 NAPHTHA HYDRO-TREATING UNIT

The purpose of this unit is to chemically treat the straight run Naphtha from the crude
distillation unit to remove compounds of arsenic, lead, sulphur, nitrogen, oxygen etc.,

18
little amount of which in the naphtha constitutes poisons to the highly expensive
catalyst of the Catalytic Reforming Unit. The naphtha is mixed with some of the
hydrogen produced in the Catalytic Reforming Unit then passed through a charge heater
to raise the temperature to reaction conditions before introduction into the NHU reactor.
The product of the unit is called hydro treated Naphtha, which is the feedstock for the
Catalytic Reforming Unit.

2.1.4 CATALYTIC REFORMING UNIT

The purpose of the Catalytic Reforming Unit is to upgrade the low octane Straight Run
Naphtha into a high-octane product, called Reformate. Reformate is used as a blending
component for PMS. The Hydro-treated Naphtha is again mixed with hydrogen, passed
through the feed/effluent exchanger and then through the charge heater to the reactors,
which are stacked to ensure easy flow of the reaction catalyst.

The structure of the hydrocarbon is modified through a series of reactions such as

Dehydrogenation, Dehydrocyclization, Hydrocracking, and isomerization. The resultant
product is stabilized and sent to storage as reformate, a high-octane PMS component.
Excess hydrogen is also produced in the reaction and this is purified and stored for use
at the KHU, NHU, Butamer, etc. a small amount of off-gas is produced and sent to the
refinery fuel gas header. The continuous catalyst regeneration system allows continuous
operation of the plant and renewal of activity of spent or coked catalyst.

2.1.5 KEROSENE HYDRO-TREATING UNIT

The unit is principally to upgrade Straight Run Kerosene to specifications acceptable for
aviation jet use. The operation is similar to the NHU in terms of removal of sulphur,
nitrogen and oxygen, and also imparts better quality on the smoke and freezing points of
the product. The raw kerosene from the CDU is mixed with hydrogen and catalytically
treated to produce Aviation Turbine Kerosene (ATK).

19
2.1.6 FLUID CATALYTIC CRACKING UNIT

This is a very important unit in the refinery and it is often termed the “cash cow” of
refining operations. The purpose of the unit is to catalytically convert Heavy Diesel Oil
from CDU and Vacuum Gas Oil from VDU into more valuable products such as LPG,
FCC Gasoline, Light Cycle Oil and Decanted Oil. The feedstock is heated in a series of
heat exchangers, then atomized by steam and injected into the Riser Reactor where
catalytic cracking reaction occurs. The reaction products and catalyst flow up to the
cyclones in the Riser disengager where the hydrocarbons separate from the catalyst.

The spent catalyst flows downwards the Riser to the Regenerator where the coke
deposited on the catalyst during the reaction is burnt off and re-circulated back to the
Riser. The hydrocarbon vapours flow upwards to the main fractionation tower where
they are fractionated into gas, gasoline, light cycle oil and bottom slurry. The gas is sent
to the Gas Concentration Unit (GCU) for further processing. This gas is the source of
feedstock for Dimersol and Alkylation Units. The propylene rich fraction of the gas is
an alternative but major source of feedstock for the polypropylene plant at Eleme
Petrochemical Company Limited (EPCL). The resultant gasoline is treated at the
MEROX Unit for removal of sulphur compounds, and then sent to the PMS pool as a
blending component. The Light Cycle Oil and the main column bottom (decanted Oil)
are used to produce Low and High Pour Fuel Oil used by the sea vessels. The Gas
Concentration Unit is an integral part of the FCCU which GCU processes gas streams
from the FCCU itself, Alkylation, Merox and Butamer Units to produce propane and
butane.

2.1.7 DIMERSOL UNIT

This unit converts propylene feed from FCCU into Dimate, a high-octane gasoline-
blending component. The process is achieved by catalytic dimerization of propylene in
a liquid phase reaction. The other products from the unit are LPG which is normally
routed to the GCU and off-gas used in the refinery fuel gas system. The reactor effluent

20
is neutralized with caustic soda and water washed before fractionation. The treated
caustic effluent is then routed to waste water treatment plant for further treatment.

2.1.8 BUTAMER UNIT

The unit processes Normal Butane into iso-Butane, required as feedstock for the
Hydrofluoric Acid Alkylation Unit. The normal butane feedstock originates from the
Saturated Gas Concentration Unit in Area 1 and is catalytically isomerized into Iso-
Butane. The reaction product is a mix of about 50% each of iso-butane and normal
butane, which goes to the HFAU for reaction.

2.1.9 HF ALKYLATION UNIT

The feedstock consists of Iso-Butane from the Butamer and Iso-Butane originally in the
saturate butane stream from Crude Distillation Unit and butanes from Gas
Concentration Unit. The reaction process is a liquid phase catalytic reaction with
hydrofluoric acid as catalyst. The iso-butane and olefin content of the butane streams
are converted catalytically to alkylate. A small stream of the HF acid is sent from the
reactor section to the regenerator where polymer components of the reaction are
removed and the regenerated acid returned to the reactor section. The products from the
HF Alkylation Unit are alkylate, n-butane and propane drag stream. The various
products are passed through treaters to eliminate hydrogen fluoride. The alkylate is a
high-octane PMS blend component.

2.1.10 OLD PORT HARCOURT REFINERY (OPHR) PLANT

OPHR consists mainly of the Crude Distillation Unit (CDUII), a Platformer (CRUII)
and a Utilities Section. At its initial commissioning in 1965, the refinery had an
installed capacity of 35,000 BPSD but was later debottlenecked to 60,000 BPSD in
1972. The process and products slate are similar to that of CDUI.

The Platformer (CRUII) processes the Straight Run Naphtha from CDUII. Unlike the
Continuous Catalytic Reforming Unit (CCRU) of NPHR, this plant is of the semi-

21
 regenerative type with a fixed catalyst bed and the catalyst regeneration is carried out
inside the reactor after a long period of operation. The product, platformate, which is
also high octane, reformate, is used as a blending component for PMS. The reactions are
also similar to the reaction in the CRU of the new plant.

The Utilities section of the refinery includes a package Boiler, Crude waste Heat Boiler,
Cooling Water System, Plant Air, Raw water System, Demineralization Unit and a Flare
Unit

2.1.11 REFINERY’S PRODUCTS, UNITS AND USES

PRODUCTS UNITS USES

Propane (C3) CDU I Fuel gas consumption for burners.

CDU II Used in blending Mixed Liquefied Petroleum Gas (MLPG)

Butane (C4) CDU I Major component in MLPG blend, used as domestic or cooking
CDU II gas.
PMS blend component & also feedstock for HFAU
Straight Run Gasoline CDU I Component for premium Motor Spirit (PMS) blend.
(SRG) CDU II PMS is a finished product and is used as fuel in spark ignition
engines.
Straight Run Naphtha (SRN) CDU I Feedstock for CRU and a component for PMS blend.
CDU II
Straight Run Kerosene CDU I Used as House Hold Kerosene (HHK) in stoves and lamps.
(SRK) CDU II Feedstock for KHU

Automotive Gas Oil (AGO) CDU I Used in diesel engines and boilers. Also, used as heating oil.
CDU II
Heavy Gas Oil (HGO) CDU I Feedstock for FCCU.
CDU II Component for Low Pour Fuel Oil (LPFO)
Atmospheric Residue (AR) CDU I Feedstock for VDU
CDU II Used as HPFO. HPFO is used as fuel for sea trucks.
Vacuum Residue (VR) VDU Component for LPFO blend
Vacuum Gas Oil (VGO) VDU Feedstock for FCCU
Aviation Kerosene (ATK) KHU Jet fuel
Hydro-Treated Naphtha NHU Feedstock for CRU.
(HTN)
Reformate (REF) CRU I Major blend component for PMS
CRU II

22
Propylene C3 FCC Feedstock for Dimersol unit
As a component for MLPG blend
Used as propylene Rich feed for Eleme Petrochemical (EPCL)
Plant.
Unsaturated C4 FCC Feedstock for HFAU.
As a component for MLPG blend and Cooling gas.
Fluid Catalytic Cracking FCC Major blend component for PMS
gasoline (FCCG)
Light Cycle Oil (LCO) FCC LPFO blend component
Main Column Bottom FCC For LPFO blend
(MCB)
Dimate DMU For PMS blend
Alkylate HFA For PMS blend

MAIN PROCESS CONTROL ROOM

The refineries operations are controlled by a Distributed Control System (DCS), which continuously
monitors the plants operating parameters. Information on operating conditions such as flow rates, levels,
temperatures and pressures are gathered and displayed on the computer consoles from which plant operators
monitor and adjust unit conditions.
Table 1: Plant units, products and uses

23
 CHAPTER THREE

3 METHODOLOGY
This report gives the details of the what I learnt during my industrial training in Fuel
plant Ⅱ (Area 5) where I was posted to at PHRC.

3.1 UNITS THAT MAKE UP REFINING FUELS PLANT Ⅱ

S/ UNIT NUMBER UNIT NAME

N
1 UNIT 10 CRUDE DISTILLATION UNIT

2 UNIT 12 CATALYTIC REFORMING UNIT

3 UNIT 17 GAS TREATMENT UNIT

4 UNIT 14 LIQUEFIED PETROLEUM GAS (LPG) UNIT

5 UNIT 61 FLARE SYSTEM UNIT

6 UNIT 70 STEAM SYSTEM UNIT

7 UNIT 72 RAW WATER SYSTEM UNIT

8 UNIT 73 TREATED WATER SYSTEM UNIT

9 UNIT 74 COOLING WATER SYSTEM UNIT

10 UNIT 75 PLANT & INSTRUMENT AIR UNIT

11 UNIT 77 FUEL GAS SYSTEM

Table 2: Fuels plant Ⅱ units.

24
3.2 THE REFINING PROCESS

3.2.1 CRUDE DISTILLATION UNIT

Figure 3b: The CDU.

THE BATTERY LIMIT

Crude is pumped into the fuel plant and it passes the battery limit before further
processes. The battery limit is the area in every plant in which pipelines carrying raw
material and finished products meet and their flows are controlled using valves. Battery
limit is literally the beginning and end of a plant.

The principle behind the use of the battery limits is safety. In preparing for a major
maintenance or rehabilitation, it is cleared of all hazardous materials and isolated from
the rest of the refinery. An operator on the unit can move to the battery limit and

25
determine if all the necessary blinds have been properly installed to save the unit.
He/she signs off on a blind list confirming full unit isolation before work begins. That
same blind list is used after work completion to make sure that every blind initially
placed is removed and accounted for before commencing the commissioning and start-
up procedure.

CRUDE CHARGE PUMPS

The plant is capable of processing 60,000 Barrels per stream day (BPSD) – 400 m3/hr
of Bonny Light Crude (in accordance with the “test-run” dated April ’84) and capable of
a turn down of 35,000 BPSD – 230 m3/hr (58%). After the crude enters the plant
through the pipes at the battery limit, it moves to two crude charge pumps
(10P501A&B); one turbine driven and the other one electric motor driven. Only one of
the pumps is run at a time and the other serves as an alternative in the case of an
emergency or is run when the other one is down for maintenance. For corrosion control,
there is injection of caustic soda (in the suction of crude oil charge pump as well as to
the desalted crude). The charge pump transports the crude from the battery limit to the
shell and tube heat exchangers of the preheat train.

PUMPS
Pumps are mechanical devices that are used to transport fluids by a mechanical action.
Pumps also move fluids from a lower pressure to a higher pressure and is responsible
for the difference in pressure. Pumps convert mechanical energy to hydraulic energy
causing fluids to flow.

There are different types of pumps in PHRC Fuel plant Ⅱ;

 Reciprocating (Dozing) pump

 Centrifugal pump

26
CENTRIFUGAL PUMPS

Centrifugal pumps are used to transport fluids by the conversion of rotational

kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy
typically comes from an electric motor or steam turbine. They are a sub-class of
dynamic pumps. The fluid enters the pump impeller along or near to the rotating axis
and is accelerated by the impeller, flowing radially outward into a diffuser or volute
chamber (casing), from which it exits.

The action of the impeller increases the fluid’s velocity and pressure and also directs it
towards the pump outlet. The pump casing is designed specially to constrict the fluid
before discharge. When the casing contains only one revolving impeller, it is called a
single-stage pump and when it has two or more revolving impellers, it’s called a multi-
stage pump.

Electric motor driven centrifugal pumps make use of electric motors which convert
electrical energy to mechanical energy. It uses EMF to create mechanical work by
turning the shaft. Steam turbine driven centrifugal pumps utilize steam momentum and
velocity to generate pump pressure. The turbine makes use of pressure drop to create
mechanical work. It uses steam and hits the impeller at a particular angle to create
mechanical work. Centrifugal pumps can also be vertical or horizontal, depending on
the exact function needed.

27
Figure 4: Major parts of a centrifugal pump.

Figure 5: Parts of the centrifugal pump.

RECIPROCATING PUMPS
28
Reciprocating which means to move backwards and forward in a straight line is the
principle behind this type of pump. It works using the suction and discharge stroke.
During the suction stroke, the piston of the pump moves backwards (negative
displacement) and it sucks fluid from the suction because as it moves backwards, it
creates a vacuum allowing the suction valve to open and fluid enters.
During the discharge stroke, the piston moves forward (positive displacement) causing
an increase in pressure. Due to an increase in the pressure, the suction valve closes and
the delivery valve to open and the fluid is forced into the delivery pipe.

Figure 6: Reciprocating pump.

PUMP MAINTENANCE

Make sure machines are properly shut-down before performing your maintenance
and/or systems check. Proper isolation is important not only for electrical systems, but
for hydraulic systems as well.
 MECHANICAL INSPECTION

1. Check and ensure that mounting points are secure

2. Inspect the mechanical seal and packing
3. Inspect the pump flanges for leaks
4. Inspect the couplings
5. Inspect and clean filters

 LUBRICATION
Lubricate the motor and pump bearing per manufacturer’s guidelines. Be sure not to
over lubricate. More bearing damage occurs as a result of over greasing than under
greasing. If the bearing has a vent cap, remove the cap and run the pump for 30 minutes
before reinstalling cap. This will allow excess grease to work its way out of the bearing.

29
VALVES

A valve is mechanical equipment used to line up or isolate a pipeline. Valve also

regulate, direct or control the flow of a fluid by opening, closing or partially obstructing
various passageways. Valves also regulate or direct flow within a system or process.
During my training, I learnt about the following valves that are used in the
plant;
1. Gate valve
2. Ball valve
3. Pnuematic valve
4. Control/ non-return valve
5. Globe valve
Other fittings and couplings I came across and used were elbows, tees, hoses, caps,
plugs, reducers and expanders.

Figure 7: Parts of a valve.

30
CRUDE PREHEAT TRAIN
These are series of heat exchangers used to preheat crude in the plant. Preheating train is
used to reduce energy consumption by using hot streams of side products and pump-
arounds to heat the incoming crude. Crude is preheated to reduce its viscosity and by
that way, improve the upstream separation performances.

HEAT EXCHANGERS
A heat exchanger is a system used to transfer heat between two or more fluids. Heat
exchangers are used in both cooling and heating processes. The fluids are usually
separated by a solid wall to prevent mixing or they may be in direct contact. Heat
exchangers are required to keep machinery, chemicals, water, gas and other substances
within a safe operating temperature. Crude preheat system in the plant is arranged in
such a manner that the temperature of at least 115℃ should be reached. With bonny
Light Crude it has been seen that the optimum temperature is 145℃. Before entering
the 10D507 (“Desalter drum”), it is normally preheated to 150℃.

Heat exchangers in the plant include;

 Shell and tube heat exchangers
 Double pipe heat exchangers
 Condensers
 Crude heater
 Boiler
 Coolers
 Reboilers

SHELL AND TUBE HEAT EXCHANGERS

The shell and tube exchangers are used in the crude preheat train of the plant. A fluid
flows through the tubes side and another fluid flows through the shell side. While
flowing, they exchange heat which means the cooler fluid gains heat from the hotter
fluid. In the plant, the crude flows through the tube side while the hotter products from
the distillation column flows through the shell side of the exchanger.
The products used in preheating are Naphtha, Kerosene, Light Gas Oil, Heavy Gas Oil
and Atmospheric Residue (Reduced crude) in that order. The shell and tube exchanger
as well as other heat exchangers are properly lagged (an application of adiabatic
processes) to avoid loss of heat. They are lagged with materials such as glass wool,
mineral wool or polyethylene foam (insulation materials). Pipes are also insulated in
some cases to prevent pipe sweating, pipe freezing and heat loss.

31
Figure 8: Parts of a Shell and Tube Heat Exchanger.

DESALTER
After the crude has been heated in the shell and tube heat exchangers, it is sent to the
desalter which is still in the preheat train. Normally, crude oil contains a small amount
of brine or residual water that is associated with the crude oil both as a fine suspension
of droplets and as more permanent emulsions.

The water contains different types of salts (especially sodium, calcium and magnesium
chloride), these hydrolyse and can liberate hydrochloric acid which causes corrosion
during processing, fouling of heat exchangers and the promotion of coke formation in
the pipestill tubes

The main purpose of desalter is the removal of these impurities from the crude oil,
through intimate washing with water in a mixing valve located at the inlet of the
desalter.

32
In operation, the mixture of crude and water enters the top of the desalter and is
conveyed to the zones of electric field by a distributor. The high alternating voltage
between the electrodes causes the finely divided suspension of dissolved salts present in
the crude to coalesce in large droplets which settle out rapidly. Maximum settling is
assisted by correct temperature control. For corrosion control, there is injection of
caustic soda to the crude to be desalted.

Desalter injection water is the water collected from the crude column overhead receiver
and then sent to desalter water tank (10D508) and/or integrated with process water
make-up. The injection water is preheated in the desalter water heat exchanger
(10E514A&B) with the water effluent coming from the desalter. Injection water is then
injected in the crude through the mixing valve while the water effluent is sent to sewer
after quench.

The product of desalter is a dehydrated and desalted crude with a low sediment content
to avoid corrosion and catalyst deactivation in further downstream processes. The crude
then moves to the crude heater.

Figure 9: Schematic of Desalter.

33
CRUDE HEATER
The crude heater is a heat exchanger that transfers heat from the combustion of fuels to
fluids contained in tubular coils within an internally insulated enclosure. The crude
heater has 3 sections;

 Radiant section: Here it involves transfer of heat by electromagnetic waves to

the convection section
 Convection section: Here it involves the movement of molecules in a gas/liquid.
Warmer parts move up and the cooler parts move down by convection currents
to be heated as well.
 Stack section: Here, stack effect takes place which is the movement of air caused
by thermal differences. Higher temperature air is less dense than cooler air. The
stack in the crude heater is to primarily exhaust combustion gases into the air.

The combustion takes place in the heater box while the coils carry crude oil line up the
internal surface of the box.

34
Figure 10: Sections of a fired heater.

In operation, the temperature is increased gradually at regular intervals not swiftly to

avoid thermal shock. It is also very important to make sure that the crude is not
overheated to avoid unwanted thermal cracking and degradation of the crude oil.

In PHRC, the heater coils comprise of four parallel passes. The crude oil at the outlet of
the heat exchangers that heat the crude again after desalting (shell-side) supplies the
crude fired heater 10H501 from which are four 6” branches dividing the crude oil flow
into four parallel heater passes. Each pass is controlled by a flow indicating controller
actuating flow control valves. Flow through the four heater passes may therefore be
balanced with respect to flow and heater outlet temperature.

In the heater, heat is supplied in order to obtain sufficient vaporization in the flash zone
of the crude column. The heater is designed to fire fuel-gas. After subdivision into four
heater passes, the streams recombine into two common outlets, then leading to a transfer

35
line and later-on to the crude distillation column. Crude outlet temperature from the
heater is controlled with a controller which resets the fuel gas pressure indicating
controller. A pressure controller, automatically adjusts the supply of fuel gas to the
heater in accordance with the request of the temperature controller.

In the convective zone of the heater there is the steam generation system consisting of
water circulation and steam superheating. Additional burners are part of the steam
generation system, which allow the production of steam and can be used during the
shutdown of the crude charge heater or to allow an increase of production of steam
during the manual operation of the crude charge heater. The crude heater total flow-rate
is 400 m3/hr (divided in the 4 passes that is 100m3hr for each pass). The inlet
temperature is193℃ while the outlet temperature is usually 335℃. The crude heater
also has peep holes (also called peep doors) at the radiant section of the heater to allow
viewing of burner flames, tubes and tube support.

CRUDE DISTILLATION COLUMN (MAIN FRACTIONATION

COLUMN)

Distillation is one of the most common separation processes based on vapour-liquid

equilibrium. It is effective in separating liquid components as long as they have
different boiling points.

Two basic processes take place in the distillation column which are stripping and
rectifying.

STRIPPING: Here the down-flowing liquid is stripped of the more volatile component
by the rising vapour. The stripping section consists of trays between the bottom of the
column and the feed tray.

RECTIFICATION: Here the more volatile component is removed through contacting

the rising vapour with the down-flowing liquid. The rectification section consists of
trays between the feed tray and the top of the column. Distillation carried out in this fuel
plant is atmospheric distillation meaning it is carried out under atmospheric pressure.
36
Figure 11: Fractionating column, reboiler and condenser.

Figure 12: Bubble cap tray Figure 13: Fixing of trays in the
column.

The heated crude enters the flash zone of the crude column at a perpendicular angle.
The vapours from the flash zone ascend the trays above where they are fractionated into
Heavy Gas-oil (HGO), Light Gas-oil (LGO), Kerosene and Naphtha. The longer the
Hydrocarbon chain, the higher the boiling point and the earlier they are drained from the
column.

37
The four side streams are drawn from the column to side cut strippers where the lighter
components are stripped off. Four trays are provided below the flash zone of the crude
column and stripping steam is injected into the bottom section to strip the lighter
components in the reduced crude.
Liquid from the tray above the flash zone is called over-flash and it is normally 3-5 vol.
% on the crude in order to have sufficient internal reflux in the lowest trays.

The crude distillation column has a total of 43 bubble cap trays of which 4 are located in
the stripping section below the flash zone.
There are 4 side cut strippers:

Naptha side cut stripper: The naphtha stripper has 6 trays and naphtha is drawn from
tray 11 of the main distillation column. Naphtha is stripped using reboiled naphtha to
maintain its purity before sending it back to the distillation column. Naphtha is reboiled
in the Naphtha reboiler using Light Gas Oil (LGO) so that the purity of naphtha is
maintained to avoid catalyst deactivation during other further processes in unit 12.

Kerosene side cut stripper: The Kerosene stripper has 6 trays and kerosene is drawn
from tray 18 of the main distillation column. Kerosene is stripped using reboiled
kerosene to maintain its purity before sending it back to the distillation column.
Kerosene is reboiled in the kerosene reboiler using Atmospheric Residue (AR) so that
the purity of kero is maintained. This purity is important because this kerosene is used
to produce Aviation Turbine Kerosene (ATK) which can freeze at high distance
(elevation) from the ground if stripped with steam.

Light Gas Oil (LGO) side cut stripper: The LGO stripper has 6 trays and LGO is drawn
from tray 28 of the main distillation column. LGO is stripped using stripping steam to
remove any other volatile organic compounds that are contaminants to the LGO hence
maintaining its purity and lowering the hydrocarbon’s partial pressure. Steam is just a
gas used to provide the heat and act as a carrier.

Heavy Gas Oil (HGO) side cut stripper: The HGO stripper has 6 trays and HGO is
drawn from tray 35 of the main distillation column. HGO is stripped using stripping
steam to remove any other volatile organic compounds that are contaminants to the
HGO hence maintaining its purity and lowering the hydrocarbon’s partial pressure.

38
The major operating conditions at normal operation for crude column and side strippers
are summarized as follows:

PRESSURE (Kg/cm2 g) TEMPERATURE (℃)

1.Distillation Column
Top 1.6 105
Flash Zone 2.0 335
Bottom (outlet) - 315

2.Draw-offs from distillation

column
Naphtha 160
Kerosene 220
LGO 288
HGO 300-310

3.Naphtha stripper
Top (6th tray) 173
Bottom 176

4.Kerosene stripper
Top (6th tray) 226
Bottom 243

5.LGO Stripper
Top (6th tray) 251
Bottom 276

6.HGO Stripper

39
 Top (6th tray) 300
Bottom 310
Table 3: Information on Distillation Column, products and strippers

PRODUCT PRODUCT FLOWRATE (m3/hr)

Total feed crude 400
Naphtha 51
Kerosene 66
LGO 105
HGO 84
Atmospheric residue (Reduced crude) 94
Table 4: Distillation Column products and flowrates.

The crude column has a pump-around system (P.A) consisting of:

 Naphtha P.A.
 LGO P.A.

Heat removal from the crude column is accomplished by these two pump-arounds in
such a manner that uniform vapour loadings exist through-out the column. These pump-
around streams are used for crude preheating. The pump-around also helps the
distillation column maintain a mean withdrawal temperature.

CRUDE COLUMN OVERHEAD SYSTEM

40
The crude column overhead vapours leaving the column at 150℃ are condensed by
means of four crude column overhead condensers arranged in two series / two parallel
formation (shell-side) and then routed to the crude column overhead receiver that is
operating at about 1.4 kg/cm2g (pressure).

The crude column overhead receiver is a decanter (three phase separator). The
condensed crude overhead product is divided into three:

1. Non condensable (off-gas) are routed to the LPG unit, where a pressure control
is calculated on the suction of the gas compressor. Should the LPG unit be
stopped or should an over pressure be established, the off-gas is discharged to
the flare while in case of low pressure, the pressure is regulated by introducing
fuel-gas from the fuel-gas system when LPG unit is in operation.
2. Condensed gasoline is withdrawn to the suction line of two pumps. One pumps
the gasoline to the gasoline stabilizer while the other pump returns back the
gasoline to the column as main column reflux.
3. Aqueous condensate, settled in the boot of the overhead condenser is routed to
the desalter water tank.

It is important to also note that a vent returns vapours to the Crude Column in the space
between 5th and 6th tray to enhance fractional distillation.

PRODUCT RUNDOWN SECTION

Four side-cut products are drawn off from the column under stripper level control.
From individual side-cut strippers each product is drawn under flow rate control and
boosted up to a sufficient pressure. Moreover, the naphtha and LGO draw-offs from the
column are routed also to the naphtha P.A. system and to the LGO P.A. system.

A. NAPHTHA SYSTEM

The draw-off line is subdivided into two lines:

a) one line goes to the suction of naphtha P.A pumps.

41
b) second line goes to the naphtha stripper under stripper level control. Naphtha
enters the stripper above the top tray. A vapour line from the top of the stripper
returns to the crude column between trays 7 and 8. From the base of the stripper,
the bottom draw-off is divided into two lines:
 one line goes to naphtha reboiler (heated with LGO product). Temperature
control of stripper actuates the control valve of circulation of LGO to the
reboiler.
 the other line going to the suction of the naphtha product pump that runs directly
to the crude/naphtha exchanger (shell side) and then to the product coolers and
then to storage.

B. KEROSENE SYSTEM
The draw-off line from the distillation column is routed to the kerosene stripper
under stripper level control, kerosene enters the stripper above the top tray. A
vapour line from the top of the stripper returns to the crude column between
trays 15 and 16.

From the base of the stripper the bottom draw-off is divided into two lines:

 one line goes to the kerosene reboiler (heated with atmospheric residue).
Temperature control of the stripper actuates the control valve of circulation of
reduced crude to the reboiler, and the flow is guaranteed by means of the
differential pressure control valve of circulation of reduced crude to the reboiler.
 the other line going to the suction of the kerosene product pump that runs
directly to the crude/kerosene exchanger (shell side), to product cooler and then
to storage.
Alternatively, before going to storage kerosene can be caustic washed in
kerosene caustic scrubbers to remove H2S as well as other sulphur compounds
such as sulphides, disulphides and thiophenes.
When fuel is burnt, sulphur combines with oxygen releasing SO2 emissions that
contribute to decreasing air quality and also having a negative environmental
and health effect as a result of pollution.

42
 C. LGO SYSTEM

The draw-off line is subdivided into two lines:

 one line goes to the suction of the LGO P.A pump.

 the second line goes to the LGO stripper under stripper level control. LGO
enters the stripper above the top tray. A vapour line from the top of the stripper
returns to the crude column between trays 22 and 23.

From the base of the stripper, the bottom draw-off is routed to the suction of the LGO
product pump. Temperature indication is located below the 6th tray. Stripping steam
from middle pressure steam line is injected to the bottom of the stripper. Its function is
to lower the hydrocarbons partial pressure gas oil flash point specifications and maintain
LGO’s purity.

The LGO discharge line runs to the shell side of LGO cooler and then to storage under.
From this header before going to the cooler, there are two offtakes:

a) a line supplying LGO for heating Naphtha stripper reboiler.

b) a line supplying LGO for heating stabilizer column reboiler. The flow to these two
reboiler is guaranteed by means of the differential pressure control which actuates the
valve on the LGO line.

D. HGO SYSTEM

The HGO is drawn-off from the tray 35. The draw-off, line is routed to the HGO
stripper under stripper level control. HGO enters the stripper above the top tray. A
vapour line from the top of the stripper returns to the crude column between trays 31
and 32. From the base of the stripper the bottom draw-off is routed to the suction of the
HGO product pump. Temperature indication is located below the 6th tray. Stripping
steam from middle pressure steam line is injected to the bottom of the stripper.

The HGO discharge line runs to the shell side of Crude/HGO exchanger, to the HGO
cooler and then to storage.

43
 When the HGO stripper is not in operation, the LGO bottom draw-off from the stripper
is routed to the suction of two pumps at the same time.

STABILIZER SECTION

The stabilizer column has been designed for producing stabilized straight run
gasoline (SRG) with a minimum content of butane in order to have the required vapour
pressure. The column is operating at total reflux. It means that no liquid is taken out
from the OVHD accumulator. The function of the stabilizer is to strip the gasoline of
light ends from the heavy ends. The rising gas becomes richer in the light component
and leaner in the heavy ends. The operating pressure of the stabilizer OVHD receiver is
controlled by pressure control with discharge of gas to fuel gas system.

The stabilizer bottom is heated through the stabilizer reboiler (using hot charge LGO
product) in order to have the requested bottom temperature. The liquid is supplied by
pumps. SRG from the bottom of the column is routed to storage via the feed/bottom
exchangers and then the gasoline cooler. the bottom temperature of the stabilizer is
controlled by a temperature controller that controls the flow of LGO product to the
reboiler.

CHEMICAL SECTION

Various chemicals are injected for corrosion prevention and other purposes

CHEMICAL INJECTION POINT PURPOSE

De-emulsifier Crude line (Charge or booster pumps) de-emulsifying of water droplets in the desalter
Caustic solution Crude line to desalter Corrosion protection
Ammonia Crude column overhead line Corrosion protection and PH control
Caustic Kerosene caustic washing Sulphur compounds removal

Table 5: Chemicals used in CDU

44
3.2.2 CATALYTIC REFORMING UNIT (CRU)

Catalytic reforming is a chemical process used to convert refinery naphtha distilled from
crude oil into high-octane reformate (also called platformate in PHRC because the
catalyst used in this unit is platinum based. Basically, this unit converts low quality
naphtha in the presence of hydrogen into high grade motor fuel or aviation gasoline
blending components.

The feed of the CRU is naphtha. Prior to start-up, naphtha can be circulated from the
charge pumps through the stabilizer feed system to the stabilizer column and out
through the stabilizer bottoms exchanger and coolers to the suction of the naphtha
charge pumps.

Cold circulation is usually carried out to sweep traces of water to low points in the
system. A warm circulation is used to evaporate the remaining traces of water that the
cold circulation couldn’t achieve. It also has the added advantage of heating up the
system at the same time. A hot circulation is used for the main refining process.
Circulation needs to be carried out under a positive pressure to ensure that the water can
be drained from the low points.

45
NAPHTHA PREHEATING

The CRU feed (naphtha) is mixed with the recycle gas (Hydrogen). Hydrogen is
necessary in order to hydrogenolyze any polymers that form on the catalyst. The
combined feed is routed to the shell side of the cold combined feed exchanger, where
the combined feed is heated by part of the reactor products stream which has previously
been cooled by passing through the hot combined feed exchanger. From the cold
combined feed exchanger, the combined feed passes to the shell side of the hot
combined feed exchanger where it is heated by the total flow of hot reactor products.
The combined feed leaves the heat exchanger at about 660℉ (350℃).

HEATER AND REACTOR SYSTEM

The combined reactor charge enters the convection charge coils where it is heated by
fuel gases and then passes through the radiant tubes of the charge heater section of the
Platformer Heater. The outlet temperature (980℉/526℃ for design) is indicated by a
temperature indicator and controlled by a temperature controller which resets a pressure
valve effectively controlling the flow of gas to the burners of the charge heater section.
The combined feed now passes to the top of reactor 1 and down through the catalyst
bed.

Heat is absorbed in the reactor, due to the predominantly endothermic reaction, and the
outlet temperature is indicated by a temperature indicator.

The process stream is now routed through the radiant tubes of the 1st intermediate
section of the platformer heater and heated to a design outlet temperature of 526℃
before being passed to the top of reactor 2.

46
The products from reactor 2 are next heated in the intermediate heater. Outlet
temperature is controlled by a temperature controller which resets a pressure valve
effectively controlling the flow of gas in the burner fuel gas supply line to the 2nd inter-
heater.

The process stream is routed through reactor 3 (downward flow). The pressure drop
across the reactor is indicated by a pressure indicator and the outlet temperature by a
temperature indicator.

The fuel gases leaving the charge heater convention section still contain a useful amount
of heat. Part of this is recovered in a waste heat section where steam is generated and
superheated before being routed into the medium pressure MP steam stream. Ten
auxiliary burners are also available from the platformer section.

PLATFORMING REACTIONS

There are four basic reactions that take place in the platforming process to an extent
dependent on the severity of the operation, the quality of the feed, and catalyst type.

1) Dehydrogenation of naphthenes

2) Isomerization of paraffins and naphtheses

a) The isomerization of a cyclopentane to a cyclohexane

b) Parrafin isomerization

3) Dehydrocyclization of paraffins

4. Hydrocracking

The effluent from reactor 3 passes to the tube side of hot combined feed exchanger. The
outlet line from the hot combined feed exchanger subdivides into two lines via:

A line which routes reactor products to tubes side of the stabilizer reboiler and then to
the tube side of the cold combined feed exchanger joining line B

47
line which by passes reactor products direct to the cold combined feed exchanger.

The reactor products leaving the cold combined feed exchanger are routed via a line to
the shell side of reactor products condensers and then a line takes the gas/liquid stream
to reactor products.

TYPES OF REFORMERS (BASED ON CATALYST REGENERATION)

There are basically two types of reformers;

Semi-regenerative reformers: Older units mostly have fixed beds of catalyst that needs
to be regenerated after a period of time, where the process will be stopped and the
catalyst will be first regenerated by burning off the coke that forms on the catalyst
during normal operation before the process continues. This is the type used in the plant
Ⅱ where I worked.

Continuous catalyst regeneration reformers: Here, so they can operate at lower reactor
circuit pressures with higher coke make, as the coked-up catalyst is moved continuously
to a regenerator section, the coke is burned off the catalyst before it is returned to the
reactor section for a continuous process. This is the type used in the newer plant in the
PHRC refinery.

REACTOR PRODUCTS SEPARATOR

This separator is a vertical column (cylindrical vessel). Cold reactor products enter
above the midpoint of the vessel via a distributor and separator into gas and liquid
phases.

The gas leaves the top of the vessel. Recycle gas is routed to the absorber column of the
gas treating section (ADIP- Amine di-isopropanol) while excess gas is sent to the fuel
gas system. The liquid phase (unstabilized platformate) leaves the bottom of the
separator and is routed to the tube side of the stabilizer bottoms exchanger.

48
STABILIZER SYSTEM

The stabilizer is essentially a distillation column intended to remove light ends from a
product. The stabilizer also has a reboiler that boils the liquid from the bottom of the
stabilizer to generate vapours which are returned to the column to drive the separation
by providing the adequate temperature for the bottom of the column. The Platformer
stabilizer is a fractionating column fitted with 30 valve trays. Unstabilized platformate
enters the stabilizer via stabilizer bottoms/feed heat exchanger at the 15th tray.
Overhead vapour is sent to the overhead condenser where it is cooled and then sent to
the stabilizer overhead receiver.

The Stabilizer overhead receiver is a horizontal cylindrical receiver. Liquid in the vessel
is returned as reflux via a turbine driven pump to the stabilizer and the gas from the
overhead receiver is sent to the fuel gas line. Stabilized platformate leaves the bottom of
the column and is subdivided into two lines;

one line is routed to the shell side of stabilizer reboiler which is heated on the tube side
with the hot product from the hot combined feed exchanger which returns to the
stabilizer column below the bottom tray. Another line carries stabilizer bottoms to the
shell side of the stabilizer bottoms/feed heat exchanger. It is then routed through the
shell side of the stabilizer bottoms coolers and then it is sent to storage.

3.2.3 RECYCLE GAS TREATING SYSTEM (ADIP UNIT 17)

The top product (off gas) from the platformer separator contains hydrogen sulphide
(H2S). This is a catalyst poison and must therefore be removed from the recycle gas
stream which circulates back through the reactors. Recycle gas from the platformer
separator is sent to the ADIP (Amine di-iso-propanol) absorber section and to the ADIP
absorber column. Recycle gas enters the column beneath the bottom trays and the ADIP
solution (lean ADIP) enters the column above the top tray of the absorber. The ADIP

49
solution absorbs the H2S gas (gas absorption/scrubbing) making the ADIP solution
“rich”.

Treated recycle gas leaves the top of the column. The recycle gas must now be dried,
because high content of water could lead to activity decline of the platformer catalyst.
The top product from the ADIP absorber column is sent to the recycle gas drying unit
that uses glycol (containing a diol i.e two hydroxyl groups) because glycol has a strong
affinity for water. The recycle gas is sent to the dying column for glycol dehydration.
Glycol dehydration provides absorption dehydration for the recycle gas. Di-Ethylene
Glycol (C2 H4 OH C2 H4 OH) chemical is used for drying of catalytic reformer recycle
gas.

When glycol comes in contact with the recycle gas, the glycol absorbs the water from
the gas stream. Once absorbed, the glycol sinks to the bottom of the column. The rich
amine (containing H2S) is ten sent to the ADIP regeneration section. Rich amine is
heated in the in the ADIP regeneration column by heat supplied from a reboiler. The
steam rises through the column and liberates H2S and CO2 (Acid gases) and is sent to
the platformer heater and then lean amine is regenerated. It is then sent back to the
ADIP regeneration column. Hot regenerated lean amine is cooled and then sent back to
the ADIP absorber column, completing the cycle.

Recycle gas leaves the top of the column and is routed to the recycle gas compressor
suction drum. The glycol solution bearing all the water stripped from the recycle gas is
sent to a specialized regeneration column designed to vaporize only the water out of the
solution. Glycol flowing down through the packing of the regenerator is reboiled in a
kettle type reboiler heated by steam and vacuum is maintained in the column by means
of an ejector. After this, glycol is pumped, cooled and is recycled to the recycle gas
drying column.

ADIP MAKE-UP

50
Circulating ADIP solution is prepared and stored in the ADIP MAKE UP PIT. ADIP
from heated drums and chemicals (antifoam agent soda ash for acid removal) are added
through a manhole. Clean condensate is added from the condensate main, while low
pressure (LP) steam enters through a LP steam main. Steam can enter at the top side of
the pit via an inlet line. This enables the contents to be mixed to give a homogenous
solution. A dip stick is provided that enters via a screwed pipe cap to measure level of
the ADIP in the pit.

ADIP make-up pump takes suction from the base of the pit and routes ADIP make-up to
the base of the ADIP regeneration reboiler which ends up in the ADIP regeneration
column.

RECYCLE GAS COMPRESSOR

Recycle gas leaves the top of the column and is routed to the compressor suction drum
that acts as a knockout drum that is used to remove any water from the recycle gas
before is sent to the recycle gas compressor.

The recycle gas compressor is a multistage compressor, steam turbine driven. A

compressor increases the pressure of a gas by reducing its volume. As a result of the
frequent collisions between molecules of the gas and also with the walls of the
compressor, the mean kinetic energy of the gas increases so the temperature of the gas
increases as well.

The recycle gas compressor is operated to maintain the desired recycle hydrogen rate to
the plaforming reaction. With the turbine exhausting to a surface condenser section, the
exhaust system operates at a vacuum (685 mmHg) created by the rapid condensation of
the steam and hence enhances the operating efficiency of the compressor. Any inert
gases present are expelled through steam jet ejectors to or after condenser which vents
to atmosphere. The condensate is pumped to the condensate suction (Deaerator).

The air or gas enters the compressor through the inlet flange and is directed into the
inlet or eye of the first impeller through a set of inlet guide vanes. The guide vanes serve
to direct the gas in the proper direction. The impeller rotates at high speed which varies,

51
 depending on the type and size of the compressor. This high rotation speed causes the
gas to be thrown outward by centrifugal force and with high velocity. Centrifugal force
creates a low pressure at the impeller inlet so that more gas is forced in by the external
pressure in the suction pipe.

The velocity is decreased and converted into pressure in the diffuser channel following
the impeller. The gas then crosses over and returns to the next impeller through a sort
of return channel, including guide vanes to direct the gas into the next impeller properly.
As the gas goes through each stage its pressure is increased.

CHEMICALS USED IN CRU

CHEMICAL USE
Propylene Dichloride This is injected into catalytic reformer recycle gas to increase the chloride
content of the catalyst. This promotes the reforming reaction. It is only
used intermittently to control the chloride content between given limits.
Di-Ethylene Glycol This chemical is used for drying of catalytic reformer recycle gas. It is
liable to contamination at any time and certainly during catalyst regeneration.
Di-IsoPropanol arsine This chemical is used for treating the recycle gas to eliminate H2 S & CO
(ADIP) Components

Table 6: Chemicals used in CRU

52
RECYCLE GAS COMPOSITION

COMPONENT % VOLUME
H2 84.8
C1 5.7
C2 4.4
C3 3.0
C4 1.6
C5+ 0.4
C6+ 0.1
Table 7: Recycle gas composition.

3.2.4 LIQUEFIED PETROLEUM GAS (LPG) UNIT

Liquefied Petroleum Gas (LPG) is a flammable mixture of hydrocarbon gases such as
propane and butane that have been liquefied. It is a fuel providing energy that can be
found in our everyday life as it is used in many household appliances for cooking and
heating. It is called liquefied gas because it is easily transformed into a liquid. As a gas,
LPG expands to 270 times its volume as a liquid.

LPG COMPOSITION

53
 COMPONENT MOL%
C1 0.00
C2 0.00
C3 30.00
iC4 and nC4 68.00
iC5 2.00
TOTAL 100.00
Table 8: LPG Composition.

The LPG unit is used to produce marketable LPG as well as gasoline blending stock
from the overhead gases of the crude overhead receiver and the crude stabilizer
overhead receiver.

This section is made up of the LPG Compressor Section, Depropanizer Section,

Debutanizer Section, LPG Rundown Section and Regasser Section.

In the LPG section, gases from the crude overhead receiver and the crude stabilizer
overhead receiver are routed to the compressor suction drum which is very close to the
compressor. This suction drum acts a knock out drum to drain water from the gas
stream. The drum has a drain line from its base which will allow any liquid to be
disposed to the quench drum while gas from the top of the suction drum flows to the
compressor first stage.

The gas from the top of the suction drum moves to the first stage of the compressor.
Compression is the process of squeezing gas molecules in order to increase gas pressure
which enables it to be moved from one place to another. The two stages of the
compressor use pistons and positive displacement to compress the gas. Movement of the
piston on the suction stroke overcomes the spring thereby preventing a backflow. On
the compression stroke the piston builds up pressure in the cylinder and then the gas is
sent to an inter-stage drum.

54
N2 is consumed during purging of the 1st and 2nd stages of the LPG compressor.
Nitrogen purging is to prevent chemical alteration of products and to prevent moisture-
related equipment damage or even combustion.

After every compression stage, the temperature of the gas increases so it is sent to an
inter-stage drum and then to a cooler to reduce the temperature and give room for
liquids to fall out before it is being sent to the next stage of the compressor. Discharge
from this second stage compression may be sent either to the fuel gas line, or sent to the
depropanizer for further processing according to the desired operation.

DEPROPANIZER

The depropanizer is a fractionating column in an LPG unit used to remove propane and
lighter components. It is very important to note that the depropanizer can run either on
fuel gas mode or LPG mode. It runs on LPG mode during start-up and then LPG mode
when the unit is stabilized.

Overhead vapours from the depropanizer column passes through the water cooled
depropanizer overhead cooler and then moves to the depropanizer overhead receiver
which is a three (3) phase separator (decanter). The uncondensed vapour from the
receiver is sent to the fuel gas line. Water is also collected from the bottom of the
receiver and sent to a sewer while hydrocarbon liquid is withdrawn from the receiver,
pumped and sent back to the depropanizer column as reflux.

The bottom product from the depropanizer containing butane and other heavier
components is reboiled in the depropanizer reboiler using low pressure steam to provide
adequate heat for the bottom of the depropanizer column. The net bottom product is sent
to the debutanizer.

DEBUTANIZER

The debutanizer is used to separate the depropanizer bottoms into butanes as the
overhead product and then pentane and other heavier components as the bottom
product. The overhead product containing mainly butanes is sent to the water-cooled
debutanizer cooler and then to the debutanizer overhead receiver. The uncondensed
vapour (top product of the receiver) is sent to the fuel gas line while the bottom product

55
(hydrocarbon liquid) is pumped then one stream returns the bottoms back to the
debutanizer as reflux while the other stream is sent to the caustic LPG scrubber in the
LPG rundown section.

The bottom product from the debutanizer column is reboiled in the debutanizer reboiler
using low pressure steam to provide adequate heat for the bottom of the debutanizer
column. The net bottom product containing C5+ is routed via a cooler to gasoline
disposal line.

LPG RUNDOWN SECTION

In this section, LPG is treated in the caustic LPG scrubber to remove hydrogen sulphide
before it is sent off to storage. Fuel gas enters the base of the scrubber and passing
through the caustic soda and demisting pad, leaves the vessel at its highest point.
Addition of fresh caustic soda is made batch-wise using the fresh caustic pump at the
C.D.U. Spent soda is withdrawn from the base of the caustic wash vessel and is
disposed to the spent caustic tank. However, if the H2S content of crude is on the low
side then caustic soda doesn’t need to be used.

REGASSER

Regasification is the process of converting liquefied LPG to gas state. The regasser is a
kettle type heat exchanger. LPG from the debutanizer overhead receiver bottom or from
the caustic LPG scrubber is regassed and sent to the fuel gas line. Low pressure steam
provides reboiling heat for the exchanger. It also has a safety relief valve for safety in
the case of excess pressure.

LPG STORAGE

LPG is stored in spherical tanks. The reason why is stored in a spherical tank is because
the liquid form gas is highly pressurized and in order to keep it in liquid form, a
spherical tank ensues uniform distribution around the tank.

In sizing LPG tanks, we need to consider the following:

56
 i. expected storage capacity
ii. maximum environmental temperature which will affect design temperature and
pressure
iii. a vapour space volume of 10% is usually considered
iv. the geometric capacity using the relationship with the storage capacity, vapour
space and density.

Material used for design: Typically, LPG tanks are made of welded steel, aluminium or
composites. Steel is by far the most common material, as it is easiest to fabricate and it
is a low-cost material.

3.2.5 FLARE SYSTEM UNIT

Flares are important devices used in oil and gas processing. They safely burn excess
hydrocarbon gases which cannot be recovered/ recycled. During flaring, excess gases
are burnt off in the flare system to produce water vapour and CO2.

This unit majorly consists of;

PRESSURE SAFETY VALVES

A safety valve is designed to open and relieve excess pressure from vessels or
equipment and to reclose and prevent further release of fluid after normal conditions
have been restored.

QUENCH DRUM

This can be used to condense the vapour discharge from a relief device for either later
return into the process after the relieving condition has passed or for disposal to the
sewer. A water quench is provided to reduce excessive temperature and the liquid
collecting at the base of the quench drum is pumped to ballast tanks under level control.
Basically, the drum is provided whenever the material being relieved is too valuable to
be burnt in a flare/too toxic to be relieved to the atmosphere in a vent stack.

57
KNOCKOUT DRUM

Knockout drum is used to remove any oil or water from flare gas or relieved gas before
it is sent to the flare header. It is specially designed to separate vapour and liquid from a
two-phase process flow. It removes entrained liquid droplets from vapour streams.

FLASHBACK SEAL DRUM/ WATER SEAL DRUM

This is used to prevent any flashback of flame from the top of the flare stack. It prevents
flames from entering the horizontal flare header. A flashback refers to flame moving
rapidly back through a combustible vapour.

3.2.6 RAW WATER SYSTEM UNIT

The source of raw water in the refinery comes from four boreholes in the refinery
named; Alpha (A), Beta (B), Charlie (C) and Delta (D) and is pumped to the raw water
feed tank. The water is injected with Caustic soda solution to control the PH of the
water. The storage capacity of the storage tank is 3,400m3. From the feed tank, water is
then distributed to the domestic water storage tank, process water and fire Water
System. The domestic water system supplies water to other locations in the refinery
such as the clinic, administrative block, gatehouse, canteens as well as other amenities.

3.2.7 TREATED WATER SYSTEM UNIT

Water needs to be properly filtered, free of ions and well treated before it can be used to
generate steam to avoid fouling and corrosion in pipes and vessels.

In the sand filter section, raw water is supplied to two filter units (Demineralization bed
filter) which are pressure vessels containing a filter bed of high-grade sand supported on
graded gravels. The sand filter removes any suspended matter present in the raw water.

58
With time, as the suspended matter accumulates, the filters would need to be cleaned.
After this, the filtered water is sent to two mixed bed ion exchanger unit which is also
called the demineralization bed. This unit de-ionises the filtered water to remove
dissolved salts. The unit consist contains a homogeneous mixture of cationic and
anionic exchange resins in bed form.

In demineralization, filters exchange positively charged hydrogen from feed water and
negative hydroxyl molecules for positive and negative contaminant molecules. It is
basically the removal of dissolved mineral solids. The water emerging from the water
exchange is ion free however, the water usually contains dissolved gases which is
removed by passing the demineralized water through a deaerator.

3.2.8 STEAM SYSTEM UNIT

Steam is the gaseous phase of water. Steam is used for stripping, steam distillation and
vacuum distillation. Steam is also used for processing, heating and also used to generate
electric power in some refineries. After the raw water has been demineralized, the
demineralized water is sent to the thermal deaerator.

THERMAL DEAERATOR

Thermal deaeration relies on the principle that the solubility of a gas in a water
decreases as the temperature increases and approaches its boiling point. In the deaerator,
when low pressure (LP) steam contacts the feed water from the demineralization bed, it
heats it up to its boiling point and dissolved gases are released from the feed water and
is vented from the deaerator. It should be noted that the condensate (from the recycle
gas compressor) is flowing continuously into the deaerator.

There are 3 types of steam is service in PHRC namely;

low pressure steam (LP)

medium pressure steam (MP)

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high pressure steam (HP)

Steam is mainly generated from waste heat boiler of the crude heater and platforming
heater. Mainly, MP steam is produced through waste-heat boiler to meet the
requirement of steam turbines and process. LP steam is produced from turbine exhaust
and through a reducing station from MP steam. In steam heater, a provision is there for
venting through a LP header.

WASTE HEAT BOILER DRUM (STEAM DRUM)

Boiler feed water from the deaerator is pumped and sent to the waste heat boiler drum
(steam drum) and the auxiliary boiler.

The steam drum is a vessel used to store steam generated by the waste heat boiler and
auxiliary boiler in water tubes. It also acts aa a phase separator for the steam-water
mixture. Separated steam is drawn from the top section of the drum and distributed for
processes.

WASTE HEAT BOILERS

Water from the steam drum is sent to the steam raising coils in the convection section of
the crude distillation unit heater and another stream to the raising coils in the platformer
unit heater. When water gets to the boilers, it is converted from liquid to steam and then
the steam is sent to the MP line. Steam is then sent back to the steam drum for storage.

AUXILIARY BOILER

Just as the word auxiliary means providing supplementary or additional means to a

certain process, the auxiliary boiler is designed to supply the difference between
refinery demand and waste heat steam production. The auxiliary boiler has an

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economizer which the boiler feed water is sent to. The economizer increases the boiler
efficiency by preheating the boiler feed water and reduces the amount of energy
required in heating, resulting in reduced fuel consumption and cost. The economizer is
routed to a steam drum and then a superheater. The superheater is used to further heat
steam to produce steam that meets the requirement of a dry steam (The superheater
converts saturated steam into superheated steam or dry steam) which is less likely to
condense within engine cylinders and casting of steam turbines. MP steam is produced
from the superheater.

BLOWDOWN DRUM

This is a vessel used to receive a periodic or emergency discharge of liquids from

process vessels and equipment. It is used to depressurize processes in a refinery.
Provision is made for blow-down from both the waste heat boiler and auxiliary boiler.
The blowdown system is designed to allow refinery to relieve any process in a
controlled and safe way that protects plant equipment and personnel. It is also designed
to prevent high pressure steam and water from entering into drains in the refinery
(vapour depressurizing). When blowdown water enters the drum, water gives up its
excess energy as steam through a vent. The remaining water moves to the bottom of the
drum. The drum returns flash steam to the deaerator and disposes off condensate to
drain.

CHEMICAL USED IN STEAM SYSTEM UNIT (BOILER CHEMICAL

DOSING FACILITY)

In the steam system unit, boiler feed pumps take suction from the thermal deaerator.
Facility for injecting Sodium sulphide solution to the boiler feed pump take suctions

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from the Sodium sulphide pump tank. The use of sodium sulphide solution is to get rid
of any residual oxygen (scavenge) in the boiler feed water.

3.2.9 COOLING WATER SYSTEM UNIT

The cooling water system tower is a specialized heat exchanger in which air and water
are brought into direct contact with each other in order to reduce the temperature of
water. As this occurs, a small volume of water is evaporated leading to a reduction the
volume of the water being circulated through the tower.

As a result of this, a make-up cooling water is needed to ensure there is adequate

volume of water in the cooling water basin for circulation in the plant. A line from the
header of the raw water storage tank supplies make up water to the cooling tower basin.
The flow is metered and controlled by transmitters which is actuated by the level in the
circulating water pump suction base.

Tower basin volume: 680m3

Cooling tower flow: 3604m3/hr

Domestic water consumption pump flow rate: 40m3/hr

There are 6 pumps that supply cooling water which are 72P526 A, B, C, D, E and F.

Pumps A & B are electric motor driven (pumping at 1364m3/hr each).

Pumps C & F are steam turbine driven (pumping at 1364m3hr each).

Pumps D & E are diesel driven (pumping at 1364m3/hr each).

Normally three pumps are kept in service.

There is turbine, electric and steam turbine driven pump so that in times of emergency
when any one fails, the others can be used to serve the same purpose of pumping till the
damaged or the pump under maintenance is ready and safe to run again.

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Figure 14: Image of Induced Cooling Tower.

Figure 15: Schematic of how the cooling tower works.

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The cooling tower uses induced drafting to cool the water coming from the plant to be
cooled. Ambient air from the bottom of the tower is pulled upwards through the tower
by the electric motor driven fan. The cooling tower also has a fill. A fill slows the flow
of water through the cooling tower and exposes as much water surface area as possible
for maximum air-water contact.

In induced draft design, the fan is at the top of the tower to pull ambient air. This design
offers a more even distribution of air across the tower.

In a forced draft design, air is pushed into the tower and the fan is below the tower in
this case.

Figure 16: Parts and arrangement of the Induced and Forced Draft design of the cooling tower.

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3.2.10 FUEL GAS SYSTEM UNIT
This is a very important unit in the refinery. This unit is designed to provide the fuel gas
requirements for the waste-heat boiler and auxiliary boiler. The fuel gas system supplies
treated fuel gas for various fired equipment applications within the plant. The gas can
come from a natural gas supply line or off gas from various processes in the plant.

Sources of fuel gas from the plant include the following;

1) Crude distillation stabilizer column overhead receiver

2) Platformer stabilizer overhead receiver

3) Platformer separator

4) LPG regasser

5) LPG depropanizer overhead receiver

6) LPG debutanizer overhead receiver

7) 2nd stage of recycle gas compressor

3.2.11 PLANT & INSTRUMENT AIR UNIT

PLANT AIR

This is basically for machines that require air that does not need to be extremely clean,
dry and usually require large volumes.

INSTRUMENT AIR

This needs to be clean and dry for pneumatic instrumentation. It is an extremely clean
supply of compressed air that is free from contaminants such as moisture and particles.

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It is used for;

 pneumatic equipment
 pneumatic valves
 electric controls

The plant and instrument air used in the plant is provided by two compressors. One is
electric motor driven while the other is steam turbine driven. The electric driven
compressor is usually in service and then the steam turbine driven compressor serves as
a spare in times of emergency.

The difference between plant and instrument air is cleanliness and dryness because
instrument air is used for pneumatic instrumentation while plant air is used for process
and breathing air. Instrument air is free of moisture which is made so by the use of air
dryer.

AIR DRYER (ADSORPTION TYPE DRYERS)

The adsorption type of dryer is a type of air dryer. Other types include, refrigerated type
dryer and coalescence filter type dryer.

The adsorption type dryer is used to remove water vapour from air and other gases.
They are not designed to remove liquid water. It is therefore necessary to make sure
that the compressed gas entering the dryer has had the liquid water and/or particles of
oil, removed first. This is accomplished by a simple mechanical separation and there are
many proprietary separators for doing this. In most compressed air circuits, the receiver
is filled with an automatic separation and drain on the outlet side.

In the air dryer, a desiccant is used for adsorption of water vapour from the air or
gas flow, and for its transfer during the subsequent regenerative cycle. The
desiccant used is Activated alumina. The gas to be dried is passed through the
bed of desiccant at a pre-determined flow rate. There is sufficient contact

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between the desiccant and the gas that is to be dried so the water vapour will be
removed to the required specification. It is also very important to note that this
dryer uses non-lubricated valves therefore, no lubrication is needed. Maintenance
and regular checks from quarterly to twice a year and biannual checks are carried
out on the dryer to make sure it functions effectively.

CHAPTER FOUR

EXPERIENCE GAINED
I was posted to Fuels Plant Ⅱ under production department. I worked with very
dedicated and committed refiners. I worked as an external operator under the guidance
and supervision of the daily chief operators. The plant is responsible for the production
of a number of products from the Crude Distillation Unit (CDU), the Platform Unit
(CRU) and the LPG Unit.

I was part of the team that carried out steaming of plant to remove trapped hydrocarbons
as part of the operations before the official handover of the plant to Maire Tecnimont,
the French engineering, procurement and construction company contracted to carry out
a full and effective rehabilitation of the refinery’s plants for improved production to
meet the mission and vision of the company.

Working with both PHRC and Maire Tecnimont staff improved my interpersonal,
communication and social skills as I worked with professionals from different
disciplines. I had a hands-on experience on operating equipment in the plant and had a

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unique opportunity to understand the refining process. I also learnt how to operate and
how to maintain water level in the plant.

I also learnt the following:

1. introduction to oil and gas processing

2. principles of rotating and static equipment such pumps and turbines and their
maintenance.
3. strong interpersonal skills and ability to collaborate with people from various
backgrounds in developing innovative solutions of high interest.
4. practical knowledge of boiler operation to generate steam and steam distribution.
5. deep knowledge and understanding of maintenance procedures for rotating
equipment.
6. proper housekeeping, health and safety skill.
7. better team work ability.
8. enhanced decision-making ability and how to manage multiple tasks
simultaneously.
9. improved confidence and office ethics.
10. ability to apply theoretical knowledge in real work situation, in so doing bridges
the gap between theory and practice

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MODELLING OF CRUDE DISTILLATION UNIT USING ASPEN
HYSYS
I carried out a steady state model of the crude distillation unit using Aspen Hysys. I did
a simulation of the crude distillation unit in the parent flowsheet environment and then a
simulation of the fractional distillation column in the column environment. The use of
this model is to improve the understanding of the crude distillation unit based on what I
learnt during my training at Fuels Plant Ⅱ at PHRC. This model is subject to further
improvement and adjustments to fit the desired use.

Figure 17: Sample modelling of crude preheat train and crude fractional distillation on
main flowsheet of Aspen Hysys version 10.
Figure 18: Sample modelling of the fractional distillation column in the column
environment using Aspen Hysys version 10.

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 CHAPTER FIVE

CONCLUSION AND RECOMMENDATION

CONCLUSION
My period at PHRC was very beneficial and breath-taking. The SIWES has positively
contributed to my training as a chemical engineer. I was able to relate theoretical
knowledge to what is done in the industry. I got a better appreciation of the principles
being taught in school. I had the privilege of seeing things from an engineering
perspective and standpoint. I also attended workshops and meetings, and got to listen
and see how issues are resolved through constructive thinking and sharing of ideas. I
was also able to develop better communication and interpersonal skills. Basically, I was
able to achieve my personal expectations and the objectives of SIWES listed in Chapter
1 of this report.

RECOMMENDATION
The exposure to the working environment and the facilities has really expanded my
knowledge and given me a platform to operate upon. Therefore, I believe that SIWES
should be encouraged in every institution of higher learning for students to get more
hands-on skills and practical experience which will go a long way to motivate learning
and increase the countries industrial growth leading to a sustainable growth in the
country’s national development. Below are some of the recommendations I made from
my observations.

1. The ministry of education should ensure that in every tertiary institution, there
are adequate apparatus to perform experiments to grow students in the technical
aspects of engineering.
2. The ministry of education should from time to time review the curriculum of
engineering and other technical based courses to improve development and
adapt to the ever-growing technological age.

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3. The lecturers should be encouraged by allocating incentives to them and also,
they should also be up to date in their department.
4. Companies dealing with software should provide the interns with laptops
containing software used by their team to aid learning if possible
5. Companies should engage interns in live projects as this will aid learning and
improve critical and constructive thinking.
6. Companies accepting students for industrial training should make effort to draw
out a plan for the students as this will help the students benefit optimally and it
also serves as a tool for monitoring progress.

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 REFERENCES

1. http://www.nnpcgroup.com/nnpcbusiness/subsidiaries/phrc.aspx
2. https://en.wikipedia.org/wiki/Oil_refinery
3. https://en.wikipedia.org/wiki/Oil_refinery#/media/File:RefineryFlow.png
4. https://www.aiche.org/ccps/resources/glossary/process-safety-
glosary/blowdown-drum
5. https://www.americanheatingco.com/industry-applications/oil-refinery-
process-heating
6. Refinery rules book (Toledo Refinery, 2006).
7. Port Harcourt Refining Company Brochure and trainee manual.
8. “Students Industrial Work Experience Scheme (SIWES) _ National Open
University of Nigeria.”
9. Nwagbo, C., Eyang, T.E., & Hategekimana, F. (Spring,2015). Production of
high-quality petroleum products from crude oil using aspen hysys. pp. 10-14.
10. Chaudhuri, U.R. (2011). Fundamentals of petroleum and petrochemical
engineering. pp. 49-76.
11. Towler, G., & Sinnott, R. (2008). Chemical Engineering Design: Principles,
Practice and Economics of Plant and Process Design. pp. 793-1060.
12. Haydary, J. (2019). Chemical process design and simulation. pp. 63-122.
13. Speight, J.G. (2020). Refinery of the future (Second Edition). pp. 39-145.
14. Borges, J.L. (2009). Fouling management in crude oil preheat trains through
stream split optimization.
15. Coker, A.K. (2010). Ludwig’s applied process design for chemical and
petrochemical plants volume.
16. Kamji, B.B (2020). Technical report on student industrial work experience
scheme (siwes) 2018/2019 session (July- December). Pp 1-3. 41-43.

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