NOIDA INSTITUTE OF ENGINEERING &

TECHNOLOGY ,Gr. NOIDA

INDUSTRIAL TRAINING PRESENTATION ON IOCL

MATHURA REFINERY , SESSION-2022-2023
SUBMITTED BY-
AMAN SHARMA
SUBMITTED TO- 1901330510002
DR.MEGHNA KAPOOR DEPT.OF CHEMICAL
ENGG.
 PRESENTATION ON

Prime Gasoline Unit

(PRIME-G)

IN REFERENCE TO IOCL
MATHURA REFINERY
OVERVIEW OF IOCL MATHURA REFINERY &

VARIOUS PROCESS UNITS

 IOCL MATHURA REFINERY

Mathura Refinery, the sixth refinery of IndianOil was commissioned in 1982 with a
capacity of 8.0 MMTPA to meet the demand of petroleum products in north
western region of the country, which includes National Capital Region. Refinery is
located along the Delhi-Agra National Highway about 154 KM away from Delhi.

Indian Oil Corporation is an Indian public sector petroleum company largest

commercial Enterprise in the nation which is 116th on the Fortune Global 500 listing
established in 1964 owns maximum number of Refineries in nation largest Cross
Country crude oil and pipeline network of 9300 km maximum number of stations in
the country 16455 gasoline and diesel station.
CRUDE SOURCE OF IOCL
Paradip-Haldia-Barauni Pipeline (PHBPL)

Mundra - Panipat Pipeline (MPPL)

Salaya-Mathura Pipeline (SMPL)

India imports around 84% of its crude oil needed also India is the third
largest Oil consumer and important in the world India's also the fourth
largest importer of LNG and year on year it has been on the rise
India imports most of its oil from ---
V I
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R C
I L

O
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F
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N N
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T R
S Y
PRIME -GASOLINE UNIT
(PRIME-G)
What is gasoline?
Gasoline is a transparent, petroleum-
derived flammable liquid that is used
primarily as a fuel in most spark-ignited
internal combustion engines.

The exact chemical composition of gasoline

is undefined but gasoline consists of a
homogeneous mixture of small, relatively
lightweight hydrocarbons with between 4
and 12 carbon atoms per molecule
(commonly referred to as C4–C12).

It is a mixture of paraffins (alkanes), olefins

(alkenes), and cycloalkanes (naphthenes).
 Purpose of Prime-G Unit

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The purpose of prime Premium gasoline is
[{"A":382.94880430300486,"B":108,"D":1694.7583007812498,"C":370.9562040625005
unit is to hydro treat fcc
,"A?":"K","a":{"A":[{"A?":"A","A":"The purpose of prime unit is with
to hydro
gasoline an treat
octanefcc gasoline
to produce gasoline to produce
low \nsulphur low with minimum R1 loss in order to meet sulphur's pack
gasoline
sulphur
level of 91 or greater, with
of less \nthan 50.gasoline with has the highest sulphur content 500 PPM amongst
\n*Fcc gasoline
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order MS pool \n\n"}],"B":[{"A?":"A","A":{"font-family":
to meet sulphur's pack of being the most common
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less versions of premium
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{"A":"45.3333"},"text-align":{"A":"center"}}},{"A?":"B","A":78},{"A?":"A","A":{"font-family":
than 50 gasoline
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 Main Challange Prime -G revamp

Is to Decrease ‘S’ in The objective of

olefinic gasoline while revamped Prime G is to
minimizing Octane loss produce EURO-VI gasoline
and hydrogen in which max ‘S’ limit is 10
consumption. PPM due to CPCB norms
Minimization of olefin imposed by Environment
Hydrogenation & aromatic ministry by the end of
saturation except 2019
Benzene

 .
*Fcc gasoline has the highest sulphur content 500 PPM
amongst the streams
that go to refinery MS pool
The various refinery streams blended to make gasoline

1. Straight-run gasoline
2. Reformate
3. Fluid Catalytic cracked
gasoline
4. Hydrocracker Feed
Of
5. Alkylate Prim
e-G
6. Isomerate
7. Butane
 Hydro-treating FCC Gasoline by
Prime G Technology of M/s Axens of
France , involves processing of FCC
Gasoline in four sections viz.
1. Selective Hydrogenation Unit
(SHU)
2. Gasoline Splitter Unit (GSU)
(Located at FCCU B/L)
3. Hydro-De-Sulphurisation Unit-1
(HDS-1)
4. Hydro-De-Sulphurisation Unit-2
(HDS-2) (Included after Revamp)
FEEDSTOCK PROPERTIES
UTILITY SPECIFICATIONS
PRODUCT SPECIFICATIONS
 SECTION -1

SELECTIVE
HYDROGENATION UNIT
Hydrogenation of diolefins to Olefins from feed to avoid
gums and polymers formation in the HDS section.

Shift boiling range of sulfur compounds by converting

light sulfur species into heavier sulfur species.

Heavier sulphur species are later hydro-treated in HDS

section.
 Selective hydrogenation is achieved in SHU reactor
Catalyst HR 845 is loaded in this reactor. The HR 845 is a mix of
nickel and molybdenum oxide on a special support.
MAJOR REACTIONS HAPPENING IN SHU SECTION
Hydrogenation of Diolefins:
Diolefins are hydrogenated into
corresponding olefins and some
of the olefins are hydrogenated
into corresponding paraffins.
These reactions are highly
exothermic.
The typical heat of reaction is 30
Kcal/mol.This reaction,
thermodynamically enhanced by
low temperatures (T lower than
200deg. C), takes place when
diolefins are almost completely
eliminated.


Hydrogenation of Olefins

These reactions are

undesirable because they
reduce the octane
number.The
hydrogenation of
diolefins is faster than the
hydrogenation of olefins.
The typical heat of
reaction is 28 Kcal/mol.
 Sulphur Shift Reactions:

The heavy sulfur compounds

produced over the selective
hydrogenation catalysts are
essentially heavy sulfides and, to a
lesser extent, heavy mercaptans.

The following mechanisms are

believed to take place:

Conversion of light mercaptans to

heavy sulfides
Conversion of light mercaptans to
heavy mercaptans
Conversion of sulfides to heavier
mercaptans
Conversion of H2S to mercaptans
 SECTION-2
GASOLINE SPLITTER UNIT
(GSU)
 A splitter is usually a simple distillation column that makes a
top and bottom product, whereby the feed has been "split" into
two streams.
GSU Split the hydrotreated naphtha into light , heart and heavy
cut naphtha, Effluent of SHU Reactors is the feed to GSU

Light Cut Naphtha (LCN): recovered as Top cut from side-

draw - tray 5
Heart Cut Naphtha (Heart Cut) : recovered as Middle Cut
(also called Middle Cut Naphtha (MCN)) from side-draw -
tray 25
Heavy Cut Naphtha (HCN): recovered at splitter bottom
 Light Cracked Naphtha (LCN)

Recovered as Top cut from side-draw - tray 5

Low sulfur content (Sweet LCN)
No di-olefins
Very low or no mercaptans content
High olefins content
Heart Cracked Naphtha (Heart Cut)

Recovered as Middle Cut (also called Middle Cut Naphtha (MCN)) from side-draw - tray 25 and
sent to side stripper for light end removal
Low diolefins
High olefins content
C6 cut, rich in Benzene (~ 4-5% vol)

Heavy Cracked Naphtha (HCN)

Recovered at splitter bottom
High sulfur content - to be treated in HDS section
Low di-olefins content
Moderate olefins content
PFD OF SHU & GSU SECTION
 SECTION -3

HDS-1 & 2
HYDRO DE-SULPHURISATION
UNIT
 Hydrodesulfurization (HDS) is a catalytic chemical
process widely used to remove sulfur (S) from refined
petroleum products, such as gasoline or petrol so as to
reduce the sulfur dioxide (SO2) emissions that result from
using those fuels in automotive vehicles.

Another important reason for removing sulfur from the

naphtha streams is that sulfur, even in extremely low
concentrations, poisons the noble metal catalysts
(platinum and rhenium) in the catalytic reforming units
that are subsequently used to upgrade the octane rating
of the naphtha streams.
 Purpose: the purpose of HDS reactor

To hydro de-sulfurise the sulfur rich HCN sulfur content

decreased by converting organic sulfur into H2S

Catalyst HR 806 is loaded in HDS Reactor. The HR 806 is a by

metallic desulphurisation catalyst consisting of cobalt and
molybdenum oxide dispersed on an active alumina support.

Molybdenum is generally regarded as the active

desulphurisation component.

Cobalt act as a promoted to increase catalytic activity.

MAJOR REACTIONS OCCURING
IN HDS SECTION
Sulfur removal is the major purpose of this reactor in order
to prepare a desulfurized stock of the gasoline pool.

However, partial olefin saturation reactions and partial

denitrogenation (denitrification) of a small amount of
nitrogen compounds that are present in the feed occur
simultaneously with desulfurization.
Desulfurization: The typical sulfur compounds in cracked gasoline are of
the thiophenic and benzothiophenic types.

Benzothiophenes are essentially converted and the residual sulfur is

essentially in the form of thiophenes and mercaptans.

Denitrification (or denitrogenation): Nitrogen is removed in catalytic

hydrotreating by the breaking of the C-N bond producing a nitrogen free
aliphatic and ammonia.

The breakage of the C-N bond is much more difficult to achieve than the C
S That's why denitrification occurs to a much lesser extent than
desulfurization.
 Hydrogenation of Olefins (Undesired)

Under the selected operation conditions, the olefin

hydrogenation level is lower than that of
hydrodesulfurization. Therefore, good selectivity is
achieved.

In order to desulfurize the FCC naphtha while maximizing

octane retention, the olefin saturation must be minimized.
H2S is a strong inhibitor of the hydrodesulfurization
reactions and favors recombinant mercaptans formation.

However, it does not decrease the olefin hydrogenation

level. As a result, H2S decreases both catalyst activity and
selectivity. For this reason, the H2S is removed from the
recycle gas through the amine absorbers.
PFD OF HDS SECTION
PFD OF PRIME -G UNIT

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