A

Report on Summer Training

INDIAN OIL CORPORATION LTD (IOCL)

HALDIA REFINERY

DURATION-15 June 2021– 15 August 2021

PREPARED AND SUBMITTED BY :-

Anjul Verma

DEPARTMENT OF MECHNICAL ENGINEERING

BRANCH:- Manufacturing Processes and Automation Engineering (MPAE)

INSTITUTE NAME- NETAJI SUBHAS INSTITUTE OF TECHNOLOGY (University of

Delhi), New Delhi

TABLE OF CONTENTS

Contents-
1. Acknowledgement
2. Certification
3. Abbreviation’s used
4. Introduction
a)Vision
b)Mission
c)Objectives
5. Overview of Haldia Refinery
a) Fire & Safety
b) Effluent Treatment Plant(ETP)
c) Facilities
d) Major products
e) Brands at IOCL
6. Haldia Refinery- Plot plan
a) Refinery Configuration
7. HGU-1
1
 a)Hydro Treating
b)Hydro Cracking
8. HGU
a) Purpose of HGU unit
b) Demand of hydrogen in refinery
c) Explosive and flammable media
9. VDU-2
a) Vacuum distillation unit
b)Vacuum System
10. Furnace
11. PDA
12. Upcoming projects
13. Contribution of IOCL towards society
14. Conclusion

2
 ACKNOWLEDGEMENT:

The internship opportunity I had with IOCL Haldia was a great opportunity to learn and
grow my practical knowledge. Therefore, I consider myself as a very lucky individual as I was
provided with an opportunity to be a part of it. I am also grateful for having a chance to
meet so many wonderful people and professionals who led me through this internship
period.

I would like to acknowledge my profound and sincere gratitude to Chari P Sandilya Sir, SK
Kujur Sir and SN Jha Sir for being my mentor and blessing me with their precious guidance
which were extremely valuable for my study both theoretically and practically. I offer
thanks and gratitude to all the respondents who extended so earnestly their co-operation
answering the queries on time and helping me in the internship period.

I perceive this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way and I will continue to work on their
improvement, in order to attain desired career objectives

Date: 29th August 2021

Place: I.O.C.L Haldia

3
4
Abbreviation Full meaning

DHDS DHDS( Diesel Hydro -Desulfurization Unit)

HGU-1 Hydrogen unit-1

CDU Crude oil distillation unit

MSQ Motor sprit quality

OM&S Oil management and storage

KTPA Kilo tonnes per annum

PPMV Parts per million volume

PSA Pressure Swing Adsorption

RCO Reduced Crude Oil

VDU Vacuum Distillation Unit

LOBS Lube Oil Base Stocks

INTRODUCTION:

This report is based on the project dissertation in I.O.C.L. Haldia. I.O.C.L is an Indian state-
owned oil and gas corporation with its headquarters in New Delhi, India. I.O.C.L is one of the
most advanced plant in India for oil refining. I.O.C.L has been using American, Japanese &
Russian technology and has he raw material that is used in plant is also imported from
Arabian countries. I.O.C.L has 10 refineries. The company is the world's 119th largest public
corporation, according to the Fortune Global 500 list, and the largest public corporation in
India when ranked by revenue. It has also earned reputation as 18th largest petroleum
company in the world and NO.1 petroleum trading companies in Asia-Pacific region. IOCL
stared its journey way back in 1959 Indian oil company Ltd. It became Indian Oil Corporation
limited in 1964.

5
 Petroleum is derived from two words – “petro” means rock and “oleum” means oil. Thus the word
“petroleum” means rock oil. This is a mixture of hydrocarbons; hence it cannot be used directly and
has got to be refined. Petroleum is refined in petroleum refinery. The purpose is to separate
crude oil into its saleable components and remove impurities detrimental to product quality.

Ten refineries are as follows:-

Head Office:-SCOPE complex, New Delhi

i) Digboi Refinery
ii) Guwahati Refinery
iii) Bongaigaon Refinery
iv) Barauni Refinery
v) Haldia Refinery
vi) Gujarat Refinery
vii) Panipat Refinery
viii) Mathura Refinery
ix) Paradip Refinery
x) Two Group company refineries: CPCL Manali (10.5 MMTPA) and CPCL
Nagaland.

Vision of IOCL:
“ A Major, Diversified, Transnational,
Integrated Energy Company, with National
leadership and a Strong Environment
Conscience, playing a National Role in Oil
Security & Public Distribution.”

6
 Mission:

✓ To achieve international standards of excellence in all aspects of energy and diversified

business with focus on customer delight through value of products and services, and
cost reduction.
✓ To maximize creation of wealth, value and satisfaction for the stakeholders.
✓ To attain leadership in developing, adopting and assimilating state of the art technology
for competitive advantage.
✓ To provide technology and services through sustained Research and Development.
✓ To foster a culture of participation and innovation for employee growth and
contribution.
✓ To cultivate high standards of business ethics and Total Quality Management for a
strong corporate identity and brand equity.
✓ To help enrich the quality of life of the community and preserve ecological balance and
heritage through a strong environment conscience.

7
 Objectives
✓ To serve the national interest in the oil and related sectors in accordance and consistent
with government policies.
✓ To ensure and maintain continuous and smooth supplies of petroleum product by way
of crude refining, transportation and marketing activities and to provide appropriate
assistance to the consumer to conserve and use petroleum product efficiency
✓ To earn a reasonable rate of interest on investment.
✓ To work towards the achievement of self- sufficiency in the field of oil refining and by
setting up adequate capacity and to build up expertise in laying of crude and petroleum
product pipeline.
✓ To create a strong R&D base in the field of oil refining and stimulate the development of
new products formulations with a minimize/eliminate their import and to have next
generation products.
✓ To maximize utilization of the existing facilities in order to improve efficiency and
increase productivity.
✓ To optimize utilization of its existing capacity and maximize distillate yield from refining
of crude oil to minimize foreign exchange outgo.
✓ To minimize fuel consumption in refineries and stock losses in marketing operation to
effect energy conservation.
✓ To further enhance distribution network for providing assured service to customer
throughout the country through expansion of reseller network as per marketing plan/
government approval.
✓ To avail of viable opportunities, both national and global, arising out of the liberalization
✓ policies being pursued by the government.

8
 Overview of Haldia refinery

• Located at Haldia, Purba Medinipur, West Bengal

• Foundation Stone laid by Late Prof. Triguna Sen, Hon’ble Petroleum Minister 6 th
December 1969

• Commissioned in January 1975

• Refinery expanded from 2.5 MMTPA to 8.0 MMTPA between 2010 and 2020
which is three times growth.

• In 1994 was the first refinery in India to achieve ISO 9002 certification first SRU
commissioned.

• In 1999 HGU& DHDS unit was commissioned and OHMS certification was
achieved.

a) Fire and Safety

• Haldia refinery has completed 3196 fire free days

• Designed a double fire contingency

• Fire water storage: 27000m^3

• To curb any mishappening in fire& safety Haldia refinery regularly sensitize

9
 people with

1. Safety pledge to every meeting.

2. Monthly safety meeting

3. Weekly safety interactive meeting with ED

4. Weekly safety interactive meeting with contractor supervisors.

5. Safety observation by multidisciplinary team at 22 locations

6. Mock Drill is performed regularly at HR

b) Effluent treatment Plant(ETP)

ETP plays a crucial role in treating industrial waste water also as sewages generated
from households. Packaged effluent treatment plants help both small- and medium-
sized industries by removing the effluents generated at their facilities. Otherwise, it
might be difficult for them to properly treat wastewater. they could also get to have
extra space for contaminated water treatment.

• Haldia refinery has been working actively on updating and maintaining its
ETP

• Haldia refinery has increased its New ETP 600m^3/hr

Which has peak capacity of 1250 m^3/hr

c) FACILITIES

• 8.0 MMTA crude refinery

• 603 Acres area.

• Own township and Hospital at 8 Km distance of refinery.

10
 • Haldia refinery processes three types of crudes:
Sweet and Sour Crude :
i) Low less than 0.5 wt% Sulfur
ii) Moderate 0.6- 1.5 wt% Sulfur
iii) High over 1.5 wt% Sulfur

• Fuel + Lube Refinery, 5 blocks of process plants: FOB,LOB,DHDS Block, OHCU

Block,& DYIP Block.

• 197 storage tanks incl LPG mounted bullets & Horton sphere

• Bitumen drum filling

• Effluent Treatment plant( Design 1250 m^3/ hr)

• Product dispatch facilities: PPL, Rail, Road, Coastal

• Captive Power Plant with :

4 boilers: 3 x 125 MT/hr + 1 x 150 MT/hr

4TGs : 3 x 10.5 MW + 1 x16.5 MW

d) Major Products

• LPG
• Naphtha- HPL Grade, BPCL, PNCP
• BS- VI MS
• ATF
• SKO + PCK
• LDO
• JBO(P)
• NFO & Marpol FO
• Bitumen (VG-10/30/40)
• Coke
11
 • Sulphur
• LOBS (Gr-II-H70, H150, H500 & Gr-III H-150 ) &LOBS Gr-I

• Crude Receipt and products dispatch mode

e) Brands at IOCL

Brands at IOCL can be broadly classified into 3 categories, viz., energy, retail,
and customer loyalty programs.

ENERGY:

(i) Xtramile

(ii) Xtrapremium

(iii) Servo

(iv) Indane

(v) Indian Oil Aviation

(vi) LNG at doorstep

12
 RETAIL:

(i) Xtracare

(ii) Kisan Sewa Kendra

(iii) Swagat

(iv) Servo Express

CUSTOMER LOYALTY PROGRAM:

(i) Xtrarewards

(ii) Xtrapower

Haldia Refinery- Plot Plan

a) Refinery Configuration:

Haldia refinery is a Complex refinery: Having Primary + Secondary process units

13
The primary and secondary processes can be classified as follows:-

HGU-1

• After processing in primary unit CDU-1 and CDU -2 product goes to secondary
units like Naptha goes to MSQ and diesel component goes to DHDS unit
There are two major processes 14
 1) Hydrogen process and
2) Thermal Cracking
Purpose
• Need to increase the automotive fuel yield& quality
• Less than 10 ppm nitrogen and Sulphur is made as
Petroleum fractions of both of them cause
i. Air pollution
ii. Equipment corrosion
iii. Difficulties in further processing ( like catalyst
poisoning etc.)
• To follow auto fuel policy

Hydrogen processing
Consists of two processes
a) Hydrotreating
o Removal of hetro atoms & saturation of carbon -carbon bonds
o Nitrogen, Oxygen & metals removed
o Olefinic & Aromatic bonds saturated to improve cetane
o Higher yield of fuel products are achieved. Degree of Hydro processing
depends upon nature of feed stock and extent of pollutants
o Used to upgrade Gasoline, Diesel and Lube base Stocks
o Hydrodesulfurization is done where Sulphur components present

o Sulphur is converted to hydrogen sulfide (H2S)

• The added hydrogen breaks Carbon and Sulphur bond and saturate them
• which creates some light ends
Note : heavier distillates make more light ends from breaking more complex
sulfur molecules

Nitrogen is converted to ammonia(NH3)

• Hydrogenation becomes more significant such as in heavy distillate

and gas oil hydrotreating.
b) Hydro cracking
15
• Severe form of hydroprocessing

• Break carbon‐carbonbonds
▪ Drastic reduction of molecular weight

▪ Reduction of average molecular weight & produce higher yields of

fuel products

• 50%+ conversion
• Products are more appropriate for diesel than gasoline

Hydrogen Generation unit(HGU)

Haldia refinery has H2 capacity, KTPA of 15+73

Purpose of HGU Unit:

To supply Hydrogen to all Hydro processing units

o DHDS

o MSQ

o OHCU

16
 o CIDW

o LHFU

o KHDS

o CGO-HDT

o DHDT

Demand of hydrogen in refinery

o Generating, recovering and purchasing of hydrogen have significant impact

on refinery operating costs. More importantly, overall refinery operations, may
be constrained by the availability of hydrogen. Primary consideration, however,
should be given to the recovery of hydrogen contained in various purge gasses,
since this is a very attractive way from the viewpoint of economy.

o Reducing low value of Bitumen production by processing VR in DCU

o In DCU, VR cracked to CN, LCGO,HCGO- resulting more distillate

o All products from DCU require de-Sulphurization

o Saturation of cracked CN/LCGO/HCGO to stable products

Parameter Specification

H2 purity, mol% 99.9 (min)

17
CO+CO2,PPMV 20 (max)

N2,PPMV 50 (Max)

Chlorine + Chlorides,PPMV 1(max)

CH4,PPMV balance

H2O,PPMV 50(max)

Explosive and flammable media

▪ Hydrocarbon Vapor

▪ Hydrogen

▪ Carbon monoxide

▪ Methane

Vacuum Distillation Unit (VDU-2)

• Vacuum: Any Pressure < Atmospheric Pressure

• Why Vacuum ?: Boiling point is inversely proportional pressure, so

decreasing pressure decreases boiling point

• How to create vacuum? Ejectors are used- Steam jet/ Water jet.
Vacuum Pumps

Purpose:-To distil the RCO under vacuum for producing vacuum

18
 distillates for preparing feedstock for LOBS manufacturing. Diesel
and VR are by products and residue respectively. Then fractions
sent to other refineries for further processing.
FEED: RCO(Reduced Crude Oil) from bottom of Crude Distillation Unit.

• RCO from CDU 1(HS)& CDU2(LS)

• VDU2 is mostly operated is HS RCO mode.
Capacity- 2.6 MMTPA ( after revamp in 2019), 325MT/hr, 352.95m3/hr
Turndown- 60% of design thruput= 210 m3/hr

Distillates:-

• Hydrocracker Unit

• Fluidized Catalytic Cracking unit

Vacuum residue:-

• Lube processing(PDA)

• Bitumen blowing unit

• Vis breaker unit

• Delayed coker unit

• FO unit

o A vacuum column

Process Description

RCO is preheated in a series of heat exchangers (pre-heat exchanger train) by

exchanging heat with the high temperature product streams and then passed
through two numbers of fired heaters (furnaces) to achieve temperature of
~250-400 C. This heated stream is flashed in a vacuum distillation column
operating with top pressure of 70 mmHg (Abs). Gas oil reflux is given at the
19
top. Also an internal pump around below the Light Oil draw tray helps to
remove heat from the column. Products like SO, LO, IO and HO are drawn from
different draw nozzles from the column. Each product is stripped with
stripping steam in their respective stripper columns to remove the lighter
components and thereby increases the flash pints of the products.

All these products are cooled in the feed preheat exchangers followed by
water or tempered water coolers. VR is drawn from the bottom of the
column and is routed to tanks after exchanging heat with the feed stream
followed by steam boilers and tempered water cooler

Vacuum distillation advantages over atmospheric

1) faster processing time.

2) utility saving slash energy saving.

3) Elimination of chances of thermal decomposition.

4) Elimination of chances of high boiler formation.

Products Usage

Fuel Based Lube Based

Prepares feedstock to FCC, Prepares feedstock to Lube

Hydrocracker plant

Products:- Products

Light vacuum Gas oil(LVGO) Spindle

Diesel Light oil

Heavy vacuum Gas Oil Intermediate oil

(HVGO)

Slop Distillate Heavy oil

Vacuum Residue Vacuum Residue

Feed Stock RCO (Reduced Crude Oil) Ex FOB - CDU Bottoms

20
 Gas Oil/ Diesel

Products Spindle Oil

Light Oil

Inter Oil

Heavy Oil

Vacuum Residue (VR) or Short Residue (SR)

Unit

Capacity 250m3/hr, with Arab Mix /Upper Zakum RCO

Pressure 70 mmHg Absolute

Temperature 360-400 C

Licensor/

Technology IPIP (Romania)

Vacuum system

Vacuum range is maintained at 25-40 MMHGA by three stages ejectors

• Primary Ejectors ( 02 nos in line, 01 standby)

• Secondary Ejectors (03 nos in line)

• Tertiary Ejectors ( 03 nos in line)

21
 Working principle: From top columns we have to remove gas hence there is
primary heater secondary and tertiary heater the gas is then condensed on two
chambers. Where water is separated from diesel and water and thus processing
from all three heaters it goes out from vent

Furnace

Balanced draft furnace:

• FD fans 02 number

• ID fan 01 number

• APH ( air pre heater)

• 19 number of burners for FG/IFG heating

22
 Working process: RCO is preheated 200-310 degrees then sent to furnace to heat at 300-
400 degree. The furnace has one FG and ID fan and one APH system the purpose of the air
preheater is to recover the heat from the boiler flue gas which increases the thermal
efficiency of the boiler by reducing the useful heat lost in the gas. Furnace is used to burn
fuel oil/gas which can be analyzed by oxygen analyzer hence we can decrease and increase
heat of furnace. The body is made of bronze and glass to prevent corrosion.

Propane De- asphalting unit (PDA)

Purpose: -To recover the valuable oil left in the Vacuum Residue from VDU bottoms.
Around 25-30 % oil is left in the VR/ SR which can’t be recovered in the VDU. The
recovered oil called DAO (De-asphalted Oil) is a very good feed stock for high viscosity
LOBS manufacturing.

Feed VR (Vacuum Residue) from VDU bottoms

Products DAO (De-asphalted Oil)

Asphalt

Unit
800000 MT/Yr
Capacity

23
 DAO is recovered by means of Extraction process with liquid

propane as a solvent. Propane dissolves the oil and rejects the

Methodology
asphalts. Propane has a reverse solubility for asphalt and thus DAO

quality improves with increase in extraction temperature.

Pressure 38 Kg/ Cm2(g)

Temperature 60-80 C

Propane to 6 to 12

Feed Ratio

Operating variables:-Temperature: Rise in extraction temperature rejects more asphalt

and thus DAO quality improves but yield decreases. Propane to Feed Ratio: Increase in
ratio increase DAO yield but degrades the quality

upcoming projects
CIDWU-II: A new upcoming project for Haldia refinery which will have capacity of- 0.27
MMTPA of waxy feed, here group III (4CST,6CST and 8CST) LOBS will be produced and also
white oil from waxy cuts.

24
 Contribution of IOCL towards society
• As The Energy of India, Indian oil accounts for nearly half of India’s petroleum
products market share, with sales of 81 million metric tonnes(MMT) in the year
2020-21. Indian oil has a group refining capacity of 80.55 MMTPA and over 15,000
KM of pipeline network dedicated to fuel India’s economic rise.
• IOCL runs many CSR projects to encourage the development of society.
• IOCL with a 33000 plus workforce, extensive refining, distribution& marketing
infrastructure and advanced R&D facilities , Indian oil plays and important role In the
society.

Conclusion

Haldia refinery, of Indian Oil is well known for its achievements during the last 52 years and
all together, IOCL is always holding the fame of best Public Sector Unit in India. Not
withstanding IOCL Haldia has incorporated and installed various extra ordinary and
efficient equipment’s , but as we observed during our internship period Immediate
replacement of the highly priced equipment’s is not at all possible, but through a proper
plan or arrangement, it could be done within the coming years. Microprocessor relay
should be installed in order to increase the reliability and stability of the power system and
the operational and maintenance instructions for such relays should be given to the people
concerned by the experts. It is obvious that IOCL Haldia has been striving hard to improve
its efficiency and performance and to give quality products to the consumers, and to
achieve the peak and to maintain its glory; the structural reforms should be coupled with
operational reforms.
______________________________________________

____________________________

-------------------------------------

25