INTERNSHIP REPORT

INDIAN OIL COOPERATION LIMITED

Gujarat Refinery, Vadodara, Gujarat.

Submitted By:
1. Gowtham Kumar Metta – B20IMT738
2. Naveen Muliki – B20IMT730
3. Sharvil Vishwas Joshi – B20IMT745
INTEGRATED MTECH IN CHEMICAL ENGINEERING

INSTITUTE OF CHEMICAL
TECHNOLOGY, MUMBAI, INDIAN OIL
ODISHA CAMPUS, BHUBANESWAR,
ODISHA.

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 ACKNOWLEDGEMENT

At the outset, It has been a wonderful experience to follow the training schedule provided by Mr.
Manoj Gawande (GM, L&D) and Mr. Ishan Bhatt(AM, L&D). We wish to express a deep sense of
gratitude & sincere thanks to him for accepting our training report. We would also like to thank all the
reporting officers for properly guiding us in the respective plant along with proper reading materials.

We would like to express our gratitude towards all those who have been a part of my training
experience and without whose help this report would never have taken shape. We sincerely thank Mr.
S.K Sarangi for giving us a golden opportunity to undergo internship at Gujarat Refinery, Vadodara,
Gujarat.

We would also like to thank Dr. Sankha Karmakar, our college internship coordinators for their
support and advice to get and complete an internship in for mentioned organization.

With sincere Thanks

Gowtham Kumar Metta – B20IMT738

Naveen Muliki – B20IMT730

Sharvil Vishwas Joshi – B20IMT745

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 INDEX

S.NO: TITLE NAME: PAGE NO:

1. ABOUT THE COMPANY 5

2. ABOUT GUJARAT REFINERY 7

3. TYPES OF UNITS IN THE REFINERY 8

4. PROCESS FLOW DIAGRAM OF THE 9-10

REFINERY
5. QUALITY CONTROL LAB(QC) 13-15

6. ATMOSPHERIC DISTILLATION 16-20

UNIT(ADU)
7. VACCUM DISTILLATION UNIT(VDU) 21-24
8. LINEAR ALKYL BENZENE(LAB) 25-26
9. MOTOR SPIRIT UP GRADATION 26-27
UNIT(MSQU)
10. HYDRO CRACKING UNIT(HCU) 27-29
11. FLUDIZED CATALYZED CRACKING 29-31
UNIT(FCCU)
12. DIESEL HYDRO TREATING(DHDT) 32-33

13. ISOMERIZATION(ISOM) 33

14. NAPHTHA HYDRO TREATING UNIT 34-35

15. SULPHER RECOVERY UNIT(SRU) 35

16. CENTRAL EFFLUENT TREATMENT 36-37

PLANT(CETP)
17. METHYL TERITIARY BUTYL 38-43
ETHER(MTBE)
18. FOOD GRADE HEXANE(FGH) 44-47

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 19. VIS-BREAKER UNIT(VBU) 48-52

20. BITUMEN BLOWING UNIT(BBU) 53-57

21. OIL MOVEMENT AND 58-59

STORAGE(OM&S)
22. REVERSE OSMOSIS(RO) 60-67

23. PROJECT 68-78

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 ABOUT THE COMPANY
Indian Oil Corporation Limited (IOCL), is an Indian government corporation. It is under
the ownership of Ministry of Petroleum and Natural Gas, Government of India headquartered in New
Delhi. The government corporation is ranked 212th on the Fortune Global 500 list of the world's biggest
corporations as of 2021. It is the largest government owned Oil Corporation in the country, with a net
profit of $6.1 billion for the financial year 2020-21. As of 31 March 2021, Indian Oil's employee strength
is 31,648, out of which 17,762 are executives and 13,876 non-executives, while 2,775 are women,
comprising 8.77% of the total workforce.

Indian Oil's business interests overlap the entire hydrocarbon value-chain, including
refining, pipeline transportation and marketing of petroleum products, exploration and production of
crude oil, natural gas and petrochemicals. Indian Oil has ventured into alternative energy and
globalization of downstream operations. It has subsidiaries in Sri Lanka (Lanka IOC), Mauritius (Indian
Oil (Mauritius) Ltd and the Middle East (IOC Middle East FZE).

In May 2018, IOCL became India's most profitable government corporation for the second
consecutive year, with a record profit of ₹21,346 crores in 2017–18, followed by Oil and Natural Gas
Corporation, whose profit stood at ₹19,945 crores. In February 2020, the company signed a deal with
the Russian oil company Rosneft to buy 140,000 barrels per day of crude in year 2020. By 1 April 2020,
Indian Oil was in absolute readiness to launch BS-VI (Bharat Stage VI) fuels in all its retail outlets in
Telangana and adopt world-class emission norms.

In January 2021, sales were registered at an all-time high of 410,000 barrels of oil per day till
26 January 2021. Delek, Qatar Petroleum, Saudi Aramco are its largest business partners with Abu Dhabi
National Oil Company and National Iranian Oil Company signing deals to deliver high production output
at end of 2020.

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 Refinery Locations

Barauni Refinery Guwahati Refinery

Bongaigaon Refinery Haldia Refinery

Koyali Refinery CPCL, Chennai

CPCL, Narimanam Mathura Refinery

Digboi Refinery Panipat Refinery

Paradip Refinery Gujarat Refinery

Refinery Divisions

Refineries Division Pipelines Division

Marketing Division R&D Division

Petrochemicals Division Exploration & Production (E&P) Division

Explosives and Cryogenics Division

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 About Gujarat Refinery

Indian Oil Gujarat Refinery was commissioned in the year 1996 and has an operating capacity
of 13 MMTA as of today. Today, Gujarat Refinery is the Mother Industry of Vadodara and is catering
to the increasing energy demand due to the fast-paced development and economic prosperity of the
vibrant state of Gujarat. The Refinery has been playing a catalytic role in encouraging over 200 small
and big industries over the course of five decades.

One of the most complex refineries in India, Gujarat Refinery has about 40 operating units. Over
the course of five decades, the Refinery has kept up with the latest technological advancements and
boasts of every modern unit and technology that is available in the Indian Oil & Gas industry today.

Gujarat Refinery is also privileged with the distinction of setting up the country's first riser
Fluidized Catalytic Cracking Unit (FCCU) in 1982 and the first Hydrocracker plant in 1993. The
country's first Diesel Hydro Desulphurization Unit (DHDS) to reduce sulphur content was set up in 1999
to meet BS-II quality of HSD. MS Quality Improvement Project comprising of Continuous Catalytic
Reforming Unit (CCRU) and revamp of DHDS were carried out in the years 2006 and 2007 respectively
to meet BS-III MS and HSD quality respectively. Further, the Resid Upgradation Project (RUP) and
MS/HSD quality improvement project were commissioned in 2010-11. Gujarat Refinery is now gearing
up for supply of BS-VI fuels and capacity expansion to 18 MMT per year.

In 2004, the world's largest single train Linear Alkyl Benzene (LAB) Plant was set up in the
refinery marking Indian Oil’s big-ticket entry into the Petrochemicals field. Today, the refinery holds
the 2nd largest market share of LAB in India and exports to over 20 countrie

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 Types of Units in the Refinery

Process Flow Diagram of Refinery

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 Process Flow Diagram of Refinery

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 UNITS AT GUJARAT REFINERY

1) Gujarat Refinery Unit-1 (GR-1)

Atmospheric Distillation Unit-1 (AU-1) 4.2 MMTPA

Atmospheric Distillation Unit-2 (AU-2)
Atmospheric Distillation Unit-5 (AU-5) 3.0 MMTPA
Catalytic Reforming Unit (CRU) 0.33 MMTPA

2) Gujarat Refinery Unit-2 (GR-2)

Atmospheric Distillation Unit-3 (AU-3) 2.7 MMTPA

Universal Product Dow Chemical 0.166 MMTPA
Extraction
(UDEX)
Food Grade Hexane (FGH) 0.03 MMTPA
Methyl Tertiary Butyl Ether (MTBE) 47 MMTPA
Butene-1 2 MMTPA

3) Gujarat Refinery Expansion Unit (GRE)

Atmospheric Distillation Unit-4 (AU-4) 3.8 MMTPA

Vacuum Distillation Unit (VDU) 1.2 MMTPA
Vis-breaker Unit (VBU) 0.5 MMTPA
Bitumen Blowing Unit (BBU) 1.6 MMTPA

4) Gujarat Refinery Secondary Process Functioning (GRSPF)

Feed Preparation Unit-1 (FPU-1) 2.0 MMTPA

Fluidized Catalytic Cracker Unit 1.5 MMTPA
(FCCU)

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4) Gujarat Hydrocracker Unit (GHC)

Feed Preparation Unit-2 (FPU-2) 2.97 MMTPA

Hydrogen Generation Unit-1 (HGU-1) 38,000 MMTPY
Hydrocracking Unit (HCU) 1.2 MMTPA
Hydrogen Generation Unit-2 (HGU-2) 10,000 MMTPY
Diesel Hydro De-sulphurisation Unit 1.4 MMTPA
(DHDS)
Sulphur Recovery Unit (SRU) 88 MMTPD
Nitrogen Unit

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 Quality Control Lab

The purpose of the QC lab is to check and approve the intermediated and Final product of the refinery.
It is an important part of any refinery as it helps to maintain the Quality of the products and rectify
quality issues if any.

Density: To measure the density of a sample, hydrometer is used.

Copper corrosion test: This method tests the corrosiveness of LPG to copper by immersion of
a polished test strip in the sample inside a test cylinder at elevated temperature. After one hour the test
strip is removed and compared against the ASTM Copper Strip Corrosion Standards. This test is
conducted for LPG, Naphtha, MS and Diesel. Process: The Copper Strip Tarnish Test assesses the
relative degree of corrosively of petroleum products, including aviation fuels, automotive gasoline,
natural gasoline, solvents, kerosene, diesel fuel, distillate fuel oil, lubricating oil and other products.
A polished copper strip is immersed in 30mL of sample at elevated temperature. After the test period,
the strip is examined for evidence of corrosion and a classification number from 100 1-4 is assigned
based on a comparison with the ASTM Copper Strip Corrosion Standards.

Sulphur test: The emissions from sulphur combustion is an atmospheric pollutant, so the
specification limits the amount present in the LPG. It is measured after the odorant is added, as the
odorant may contain some sulphur. It is essential that the total sulphur content is measured in LPG as
a liquid, not as a vapour. This test is conducted for LPG and FO. XRF is used to measure the sulphur
content. Process: The sample, in sample cup, is placed in the beam emitted from the X-ray source.
The resultant excited characteristic radiation is measured, and the accumulated count is compared
with counts from previously prepared calibration samples to obtain the sulphur concentration in mass
%.

Research Octane Number (RON): The Research octane number (RON) describes the behavior of the
fuel in the engine at lower temperatures and speeds. RON is determined by running the fuel in a test
engine with a variable compression ratio under controlled conditions, and comparing the results with
those for mixtures of iso-octane and n- heptane. The higher the octane number, the more compression
the fuel can withstand before detonating (igniting). In broad terms, fuels with a higher octane rating
are used in high performance gasoline engines that require higher compression ratios.

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 Flash point: It is the minimum temperature at which the petroleum fluid ejects/emits/generates
sufficient vapors so that when a pilot flame is brought near the air-vapor mixture, a momentary flash
occurs. This test is conducted for SKO, Diesel, FO and Bitumen.

Process: The Pensky-Martens Flash Point Tester consists of a closed-cup test arrangement that
contains any vapors produced and essentially simulates the situation in which a potential source of
ignition is accidentally introduced into a container. For this test, a test portion is introduced into a cup
and a close-fitting lid is fitted to the top of the cup. The cup and test portion are heated and stirred,
apertures are then opened in the lid to allow air into the cup and also the ignition source to be dipped
into the vapors to test for a flash. The closed-cup test like the Pensky-Martens predominates in
product specification and regulations due to its greater precision and its ability to detect contaminants.

● ATF Testing:

1. JFTOT: Jet Fuel Thermal Oxidation Test (JFTOT) is a test method for
measuring the high-temperature stability of gas turbine fuels. JEFTOT stands for Jet fuel thermal
oxidation testing. All oils deteriorate in service due to oxidation. Oil is always in contact with air
during use and most frequently combines with oxygen. This oil oxidation forms insoluble and soluble
materials that form deposit on the engine. The fuel is pumped at a fixed rate through a heater, after
which it enters a stainless-steel filter where fuel degradation products may become deposited. The
essential data derived are the amount of deposits on an aluminum heater tube which is then visually
rated.

2. BOCLE Test: Fully Automatic Test Equipment for Measurement of Lubricity

of Aviation Turbine Fuels by the Ball-on-Cylinder Lubricity Evaluator according to ASTM D-5001.
The BOCLE measures the actual wear scar size with a test ball specimen.

3. POURPOINT: Pour point is defined as the lowest temperature at which the test
fluid can be poured under the prescribed test conditions. It is one of the properties that determine
the low temperature fluidity of a lubricating oil.

4. FLASHPOINT: Flash point is the lowest temperature at which a liquid can

gives off vapor to form an ignitable mixture in air near the surface of the liquid. The lower the
flash point, the easier it is to ignite the material.

5. FREEZING POINT: the temperature at which a liquid turns into a solid when
cooled.

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 Pour and Cloud point: Cloud point is taken as the temperature below which wax in fuel tends
to form a cloudy appearance. This is a condition which is detrimental for any engine as solidified wax
makes the fuel thick and it clogs the fuel filters and injectors. This wax also gets applied on the
pipeline and has a tendency to form an emulsion with water. This is a property that holds great
significance in cold weathers. Cloud point is also referred to as Wax Appearance Temperature
(WAT).

Pour point is the lowest temperature at which the fuel continues to flow. Pour point of a fuel is an
indication of the temperature at which fuel can still be pumped. Alternately, pour point can also be
described as the lowest temperature at which a fuel performs satisfactorily and beyond this
temperature, the fuel stops flowing and starts to freeze.

Absolute and Kinematic viscosity: Absolute viscosity is measured under vacuum at 60° and
kinematic viscosity is measured at 135°C. A vacuum capillary viscometer is used. Kinematic test is
also tested for FO. The test is conducted at 175°C.

General Tests:

1. Distillation Analyzer: The distillation analyzer measures boiling points or

ranges of petroleum products in the light to middle distillate ranges.

2. Sim-Dist (Simulation Distillation): For measuring the true boiling point

distribution of crude oil and petroleum refining fractions by gas chromatography.

3. Auto-vacuum distillation: This checks the range of boiling points for

petroleum products that can be partially or completely vaporized at maximum liquid temperature of
400°C.

4. True Boiling Point: True boiling point distillation distills crude oil from the
initial boiling point up to 370-400°C. It is most commonly used to test crude oil and crude oil blends.

Pollution Control lab: Water is used for various purposes in the refinery. The water should be
tested before being sent to various units. The parameters checked are: pH, Oil and grease, BOD,
COD, TSS, Phenols content, Sulphides, TDS, Turbidity, Ammonia as nitrogen, Chloride content, Pt-
Co color.

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 Primary and Secondary Units

Significance of Primary Processes

The purpose of the Primary unit is to separate the crude into hydrocarbon compounds of different
boiling point ranges (called “fractions” or “cuts”), it is the first step in refining and is also called
the mother unit.
Primary units are also referred to as mother units and the sum of the capacity of all atmospheric
units is the crude processing capacity of the refinery.

Under mother unit:

1) Crude Distillation Unit (CDU)/Atmospheric Distillation unit (AU): Units [AU-1, AU-
2,AU- 3, AU-4 (CDU), AU-5]

2) Vacuum Distillation Units (FPU-1, FPU-2, VDU)

1) Atmospheric Distillation Unit

Atmospheric distillation is the first and most fundamental step in the refining process. The
primary purpose of the atmospheric distillation tower is to separate crude oil into its components
(or distillation cuts, distillation fractions) based on relative volatility for further processing by
other processing units.

All crude oil processed must first go through Atmospheric distillation. AU typically provides
most of the feed for the other process units in the refinery. In most refineries, the bottoms from
the atmospheric distillation tower will be sent to the vacuum tower for further separation.

We visited all the AU units in the Refinery. The products of AU are:

1. LPG (liquefied Petroleum Gas) C3, C4

2. Light Naphtha C5 -120 OC
3. Heavy Naphtha 120 -150 OC

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 4. Kerosene 150-280 OC
5. Light gas oil 280 -320 OC
6. Heavy gas oil 320 – 370 O C
7. Atmospheric Residue (RCO) >370 O C

FEED – Crude Oil (Carbon-84%, Hydrogen-11%, Sulphur-4.7%, Nitrogen-0.2%, other elements (0.1%).

Block Flow Diagram Of Atmospheric Unit

This unit mainly primarily consists of the following:

1. Preheating section, Crude Preheating

2. Desalter
3. Furnace
4. Main fractionator column, Atmospheric Distillation

The separation of crude oil by atmospheric distillation into groups of hydrocarbon compounds
of different boiling point ranges (called “fractions” or “cuts”) is based on relative volatility,
boiling point, and condensation temperature. Most of them are lighter than crude accepting the
bottom product i.e., Long Residue.

1. Crude Preheating
The purpose of this Section is to heat the crude to the desired temperatures and remove metal salts with
the help of electrolysis.

● To reduce residual water /soluble salt content to a desirable level

● To reduce the number of suspended solids
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 Crude Preheat Train 1: Crude is heated to 120.5 - 138.8 C using Shell and Tube Heat exchanger in
which the hot distillate exchanges its heat to the Cold crude in Counter Flow Direction. The heat provided
improves oil fluidity, reduces viscosity, and helps to mix water before entering the Desalter.

Crude preheating Train 2: After removing water and salts in the previous section the crude is further
heated from 128ºC to 184ºC by exchanging heat from LGO & crude is heated from 128ºC to 228.7ºC by
RCO of the column.

2. 2 - Stage desalter: In a refinery, crude oil containing high levels of salt will go throught desalter
before being fed to the Main Fractionator Column. Removal of salts is important for reducing corrosion
in the distillation column and downstream processing units. If not removed, the salt will form acids when
heated that will result in corrosion. The salts that are most frequently present in crude oil are calcium,
sodium and magnesium chlorides. Desalting also removes suspended solids such as sand, dirt, and rust
particles picked up in transport. The purpose of desalting is to remove these undesirable impurities,
especially salts and water, from the crude oil prior to distillation. The salt content in the crude oil varies
depending on the source. After preheating the crude and mixing thoroughly with water the mixture enters
the desalter vessel where heavy metal salts are removed.

Crude oil to be desalted is heated to a temperature of 100-150°C and mixed with 4-10% fresh water, which
dilutes the salt. In the vessel crude and water form two layers because of the density difference and the
salts get dissolved in water and are flushed from the bottom of the vessel which is further processed. An
electrostatic field is applied by electrodes in the settling tank, inducing polarization of the water droplets
floating in the larger volume of oil. This results in the water droplets clumping together and settling to the
bottom of the tank.

3. Furnace:

The purpose of a furnace is to attain a higher processing temperature in comparison to open-air systems.
Industrial Process Furnaces are also called Fired Heaters or Direct Fired Heaters.

Furnace designs vary as to its function, heating duty, type of fuel and method of introducing combustion
air:

1. Natural draft furnace

2. Forced draft furnace
3. Induced draft furnace
4. Balanced draft furnace

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 A furnace has a radiation zone, where the tubes receive almost all its heat by radiation from the flame,
and a convection zone where the heat from the flue gas of the furnace is transferred to the tubes by
convection. The feed to the furnace passes first through the convection zone where it attains a certain
temperature and then flows to the radiation zone for further heating.

Soot blowers are found in the convection section. As this section is above the radiant section and air
movement is slower because of the fins, soot tends to accumulate here. Soot blowers utilize flowing media
such as water, air or steam to remove deposits from the tubes. This is typically done during maintenance
with the air blower turned on.

The furnace present is a balanced draft furnace consisting of an Air Preheater, FD (force draft) fan,
ID (induced draft) fan. The furnace has 2 sections: convection and Radiation section. This furnace is box
type having four parallel passes, 1 9 burners that use both Fuel Gas and Fuel oil, and 144 pipes. the crude
enters from the top and leaves the furnace from the bottom at 375°C.The temperature of crude should be
more than 400℃ as it may cause cracking leading to coke formation The air is heated to 176℃ before
sending in the furnace through the pre-heater which uses flue gas of furnace in counter-current to
atmospheric air.

4. Atmospheric Distillation and Main fractionator Column:

The heated crude is flashed in the column at the 6th tray. Flashing causes the lighter components to
evaporate and heavier components to collect at the bottom of the column. As we move upward the
temperature of the column decreases causing distillates to condense as per their boiling points and are
removed from the side. As the vapor moves upward it also exchanges heat with the liquid coming down.
The column consists of 51 trays, from the overhead of column C1, C2, LPG, and Light Naphtha are drawn,
from 34th tray Heavy Naphtha is drawn, 26th tray Kerosene/ ATF is drawn, and 15th tray Gas oil is
removed.

Heavy naphtha, SKO/ATF, and Gas Oil Are stripped in their specific stripper where lighters are put back
in the column above the extraction tray of each product and a small amount from the bottom of each
stripper is sent back to the column as reflux that helps to improve the purity of the product. The gases
from Top passes through the fin fan cooler and condenser and are stored in a pressurized vessel
(atmospheric column reflux drum). The gases in the vessel are vented to flare gas header and the
unstabilized naphtha is sent as reflux stream and another stream to naphtha stabilizer. Water is collected
in the boot which is drained and sent to sour water header.

Naphtha Stabilization: This section removes LPG from the naphtha stream making it stabilized. The

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 unstabilized naphtha (LPG+ Light naphtha) is first heated at 119℃ and is flashed at the 20th tray the LPG
separates from Naphtha is collected through the overhead section and Light naphtha is drawn from the
bottom of the Column, the column also consists of reboiler and reflux system.

Product treatment:

● LPG Amine, Caustic, and water Washing: The overhead vapors are cooled and
stored in a stabilizer reflux drum which then goes for Amine wash wherein the cross current where H 2S
in LPG is removed. Then the LPG goes for Caustic Washing where Sulphur components like hydrogen
sulfide/methyl & ethylmercaptan and another chemical to Sodium sulfide carries droplets of Caustic
solution which is removed in water washing.
● Light Naphtha, Kero/ATF Caustic Wash: All these substances are mixed with
Caustic Solution and a residence time is given of 90 to 45 min to separate oil and Caustic solution. Caustic
wash is used to remove sulfur components like hydrogen sulfide/methyl ethyl mercaptan and another
chemical to Sodium sulfide.

Chemical dosing:

1. De-emulsifier: A de-emulsifier is injected in the crude line at the crude pumps common
suction header in desalter. De-emulsifier helps in faster de-emulsification inside the desalter, thereby
helping in faster removal of water injected for dissolving salts.

2. Caustic injection: Even after the desalter some salts are present in the crude. MgCl2 and
CaCl2 which are not removed in the desalter releases HCl due to hydrolysis on heating. This HCl can result
in corrosion of the column and pipelines. Thus, caustic injection is done after the desalter to convert MgCl2
& CaCl2 into NaCl and hydroxides of Mg and Ca. NaCl is comparatively stable and hydrolyses at a
temperature above 400°C. In the column the highest temperature is 380°C thus making NaCl completely
harmless.

3. Corrosion inhibitor: Some amount of MgCl2 & CaCl2 which wasn’t successfully removed
from the crude enter the column and hydrolyze. HCl released due to hydrolysis corrodes the top of the
column. To prevent this a corrosion inhibitor is injected at the topof the column. HCl is corrosive only in
its liquid state and thus corrosion inhibitor is required only in the upper portion of the column.

4. Ammonia solution: Ammonia is injected at the top of the column to maintain the pH in the
range of 6-6.5. This is necessary as the corrosion inhibitor is active only in that pH range. Ammonia
neutralizes the trace amount of HCl by converting it into NH4Cl salt.
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 FPU (Feed Preparation Unit) /VDU (Vacuum distillation Unit)

The Vacuum Distillation Unit (VDU) of Gujarat Refinery was commissioned in 1979. The unit was
designed to process 800,000 MTPA of RCO (50:50 North Rumaila and Arab Light). The unit produced
Light Vacuum Gas Oil (LVGO); used as LDO blending component, Heavy Vacuum Gas Oil (HVGO); used
as VBU feed and Vacuum Residue (VR); used as Bitumen Feed and VBU feed stock. After commissioning
of FCC unit, HVGO from VDU is used as one of the feed components of FCCU. The yield of desired
quantity of HVGO for FCC feed was very low.

In 1994, low cost revamp of VDU was undertaken to meet the following objectives:
• To increase yield of Vacuum Gas Oil (VGO) of desired quality for FCCU feed stocks.
• To improve VR quality for BBU feed.
• To increase unit throughput.
• To increase energy savings by using redundant equipment’s from other projects.
After revamp, VDU can process 880,000 MTPA of RCO. LVGO and HVGO are used as FCCU feed stocks.
In addition, provision is made for routing LVGO to HSD as blending stock.
In 1999, low cost revamp of VDU was undertaken to meet the following objectives.
Throughput enhanced from 0.88 MMTPA to 1.2 MMTPA.

• To increase VGO yield and improvement of its quality.

• Reduce less than 370 OC cut in VGO.
• Better bitumen feed quality.
After revamp VDU can process 1.2 MMTPA of RCO, Heavy diesel as top product used as HSD,
LVGO+HVGO used as VGO for FCCU feed stocks. In the present column, there is a provision for
withdrawal of four side cuts viz. Heavy diesel from top, LVGO, HVGO and slop distillate. Bigger wash
zone provided to maintain VGO quality as well as VR quality to suite Bitumen production.
In October 2004, VDU Air Pre heater (APH) revamp was done for increasing furnace efficiency and to
recover heat from stack flue gas.

FEED AND PRODUCTS

The Vacuum Distillation Unit (VDU) is originally designed to process Reduced Crude Oil (RCO) obtained from Crude
Distillation Unit (CDU) while processing imported crude. However, RCO obtained from various imported crude and
indigenous crude (Bombay High, North Gujarat, South Gujarat mix.) has been processed successfully.

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By distilling the RCO under vacuum in a single stage column, it produces Heavy diesel, Light Vacuum Gas Oil
(LVGO), Heavy Vacuum Gas Oil (HVGO) and Vacuum Residue (VR). Slop cut (distillate between HVGO and VR)
production facility has been provided since 1988.

UTILITIES AND THEIR CONSUMPTION

Sr. No. Utility Consumption Uses

1 LP Steam, T/hr 2.5 Stripping

2 MP Steam, T/hr 10.0 Ejector, Atomizing, Soot blowing, Velocity,
Snuffing and Emergency
3 Cooling 1400 Condensers,
wat er, cu.m/hr Coolers and Pumps

4 DM water 10.0 Steam generation and Tempered water

5 Fuel Oil, T/hr 1.7
6 Fuel Gas 300-800

PROCESS DESCRIPTION

Cold RCO is received in the feed surge drum under level control from storage tanks. Hot RCO may be
received from the Crude Distillation Units. RCO is pumped by charge pumps to a series of preheat
exchangers and then to furnace from where feed goes to the main column.
n the 1st heat exchanger LVGO exchanges heat with RCO where RCO is in the shell side and LVGO+Pump
Around (PA) in the tube side. In the 2nd heat exchanger HVGO withdrawn from column heats RCO in the
shell side. Then in the next heat exchanger slop cut exchanges heat with RCO followed by heat exchange
with vacuum residue (VR).
At the end of the preheat train, feed is heated upto 305 OC in case of hot feed and up to 292 OC in case of
the cold feed.
Preheated RCO is split into two passes and introduced to Vacuum Heater i.e furnace under pass flow control
for each pass. MP steam is injected in each pass to increase velocity and encourage vaporization of feed in
the coils.
Coil outlet temperature of ( 395-398) OC is maintained at the furnace outlet. Partially vaporized RCO is
introduced in the flash zone of the vacuum Column.
LP steam is superheated up to 350 OC in the convection coils of furnace and used as stripping steam
in the stripping section of the vacuum column.
Vapourized RCO along with steam rises through the vacuum column and is fractionated into four nos. of
withdrawals.

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1st withdrawal is Heavy Diesel which after exchanging heat with feed in the heat exchangers is cooled to
55 OC. One part is fed to the top of the column as cold Circulating Reflux (CR) and another part is fed as
Internal Reflux (IR). Balanced Heavy Diesel is sent to the storage under flow control.
2nd withdrawal is HVGO+PA by pumps. HVGO is bifurcated into two streams. One stream is returned as
IR to column and another stream is returned to the column as cold CR after exchanging heat with RCO.
HVGO also exchanges heat with water and generates steam in one bundle. Subsequently, it is cooled in
HVGO cooler and sent to the storage under flow control.
3rd withdrawal is LVGO by pumps. One part is returned as IR along with cold HVGO and another part as
cold CR. Third part goes with HVGO rundown as VGO (Vacuum Gas Oil). VGO may be routed to FCCU
(Fluidized Catalytic Cracking Unit), VBU (Vis- Breaker Unit), LSHS and slop.
4th withdrawal is the slop cut through chimney trays by pumps. Slop cut withdrawn is routed to
LSHS/FO/LDO pool. A stream of slop cut is returned back to the column as IR in flash zone.
Vacuum Residue (VR) is withdrawn as column bottom by pumps. After preheating the feed in a series of
heat exchangers, a quench stream is routed back to the column to maintain bottom temperature of 355 OC
to avoid coking in the column boot.
Further VR goes to the LP steam generator an gets cooled upto 150 C. VR is routed as follows:

Before getting cooled:

• Hot VR to BBU under flow control
• Hot VR to VBU under flow control
• Hot VR to VR burning facility
• Hot VR to IFO drum
After getting cooled:
• Direct VR injection in BBU
• After cooling in the tempered water cooler, VR is routed to storage as 130 OC.
Tempered water, required for cooling is obtained from tempered water tank. Hot tempered water is cooled
with cooling water in the tempered water cooler to maintain temperature of hot circulating tempered water.
The desired vacuum is obtained by pulling vacuum by multistage ejectors, pre- condensers, intermediate
condensers, after condensers and hot wells.

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 PROCESS FLOW DIAGRAM

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 Secondary Units

1) LAB (Linear Alkyl Benzene) Unit

LAB stands for Linear Alkyl Benzene. It is the most common raw material in the manufacture of
biodegradable household detergents. Linear alkyl benzenesulfonate (LAS), is the most cost-effective
surfactant available for use in detergent formulations.

FEED: Kerosene, Benzene

LAB processing consists of FRONT END and BACK END

FRONT END consists of 3 units.

1. Pre-fractionation- Kerosene prefractionation is often used to strip light ends and heavier
components so that the heart cut, containing then-paraffin for the production of LAB of a certain range
of molecular weight, is produced. Nitrogen flow in excess of the requirement is fed to the pre- frac stripper
receiver to control the pressure. This is done to sweep air out of the system to minimize

Union-fining- Olefin saturation, desulphurization, aromatic saturation, and denitrification take place
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along with the removal of Sulphur and Nitrogen. The Nitrogen and Sulphur convert into NH3 and H2S
which then dissolve in the liquid and are passedto the liquid separator. Normal Paraffin and Non-
Normal paraffin get separated from the feed.
2. Molex-The denitrogenated and desulphurized paraffin contains iso and neo paraffin isomers.
This Molex bed only allows linear paraffin to pass through them by the process of adsorption. Adsorbed
materials are sent to PACOL units whereas raffinates to raffinate column and extract to extraction
column. Thus, normal and non-normal paraffin got separated.

BACK END consists of 3 units

3. Pacol (Paraffin converted to Olefins)- paraffin are dehydrogenated to desired mono olefins,
di and tri olefins are again converted to mono olefins by Ni catalyst along with non-excessive hydrogen.
DMDS is also injected to prevent the conversion of monoolefins to mono paraffin.

4. PEP (Pacol Enhancement process)- Mainly the unit is set up for the removal of aromatics
using adsorption process with the use of silica adsorbent. Benzene gets separated and a treated product
known as percolate is taken forward.

5. Detal (Detergent Alkylation)- There are 3 columns –Benzene Column where the olefins are
treated with to form LAB, HAB paraffin, the leftover paraffin is sent to RPC(Recycle Paraffin Column)
where paraffin are separated from LAB and recycled into the feed, LAB column is where the product
LAB is clay treated to bring down the bromine index and separated heavier and lighter LAB

2) MSQU (Motor Spirit Quality Upgradation) Unit

MSQU stands for Motor Spirit Quality Upgradation unit. Its objective is to upgrade the naphtha by
increasing its octane number to higher octane/ low benzene/low olefins MS component and minimum
benzene as it is carcinogenic in nature.

Feed: Straight Run Naphtha, Hydrocracked Naphtha, Prefac. overhead of LAB, the bottomof naphtha
splitter of ISOMER.

By-product: Hydrogen, LPG Product:

Heavy Reformate Consists of mainly 4 sections

1. FCC gasoline splitter: C-1 to C-6 are removed from overhead and after passing through
fin fan return as total reflux back to splitter and C-7 to C-9 hydrocarbons from the bottom are sent to
NHTU surge drum.

2. NHTU: Straight run Naphtha received from CRU storage tanks along with bottom stream
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from FCCU gasoline splitter (part of MSQU plant) is hydro-treated in Reactor toremove sulphur,
Nitrogen, moisture & metals which are poisonous to the Platformer catalyst. In NHTU the olefins
/ di-olefins in the feed are saturated. Hydro-treated naphtha is stripped to remove H2S and sent to CCRU
for reforming. The H2S in the sour gas is absorbed with lean amine from SRU and the rich amine is sent
back to SRU for regeneration.

Metals are removed in the first bed and Sulphur, nitrogen removal takes place in the second bed with
the help of Co-Mo and Ni-Mo catalyst because sulfur decreases the reactivity of platinum catalysts, and
nitrogen poisons it. This is done at highpressure. Lost hydrogen is compensated with the help of the
makeup gas compressor after our feed comes out of the separator.

3. Merox: Excess Sulphur gets removed but this is not in line at present

4. Platform Section consisting of Reformer, PSA, CCRU: Endothermic reaction takes place,
hydrogen is recovered, LPG is Stabilized and hydrogen purity is increased with the help of Pt and
Alumina based catalyst. Hydrogen recovery and purification: The hydrogen rich excess gas generated
in thereforming section is sent to the recontacting section where it is compressed andcooled and
contacted with separator bottoms liquid to increase reformates and LPG yield. Hydrogen rich gas is
further sent to recovery plus a section to recover lighter.The Excess gas is treated in chloride treater to
remove chloride and is further processed in hydrogen recovery section (PSA) to recover hydrogen and
sent to existing hydrogen network, Pressure Swing Adsorption (PSA): Mixture of CO, CH4, CO2, H2O and H2
enters Pressure Swing Absorption. It consists of 12 beds, wherein three beds are used for absorption at a time. Absorption
beds absorbs CO, CH4, CO2 when it exerts pressure and pure H2 is obtained. PSA off gas is compressed and sent to
the refinery fuelgas network. After cooling in the fin fan, feed enters into the separator where H2 gases
is removed from top and reformate is sent forward into debutanizer, and Deethanizer. Vapours and LPG
got removed and after passing through the reformate splitter our Heavy reformate is sent to run down. The
product is Heavy Reformate which is sent to MS Pool directly for blending.

3) Hydrocracking Unit (HCU)

Gujarat refinery, the hydrocracker upgrades VGO through cracking while injecting hydrogen. This
yields a high volume of high-quality diesel and kerosene product. The hydrocracker is particularly
valuable in a refinery that is trying to maximise diesel production and reduce residual fuel oil. The
hydrocracker yields a high volume of kerosene and light gasoil (distillate) of good quality (high cetane
and low sulfur). However, its volume yield of naphtha is low and of low quality (low N+A).

Feed: HVGO (Heavy Vacuum Gas Oil), LVGO (Light Vaccum Gas Oil) Products: LPG, Light

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Naptha, Heavy Naptha, ATF/SKO, Diesel (main)

The Hydrocracking unit is a 2 Stage Hydrocracker with 98% conversion, the Vacuum GasOil is heated
through a series of heat exchangers and is then stored in FEED SURGE DRUM (FSD), the VGO passes
through a metal mesh candle filter to remove particles up to 25 microns in the stream. In the pipe, Recycle
Gas is added which mainly consists of Hydrogen mixture of hydrogen and VGO is again heated in
Furnace to 374C.

This mixture enters the 1st reactor consisting of 3 Beds, the first 2 beds remove impurities (sulfur,
Nitrogen, and metals) through Hydrotreating which acts like poison tothe further catalyst, and the 3rd
bed is where the cracking- breaking of longer chains into shorter- starts. 40% cracking happens in the
first reactor. Quenching lines are given in each reactor to control the temperature as hydrocracking is an
exothermic reaction. The cracked material from reactor 1 goes to the distillation column where LPG,
Heavy naphtha, Light-Heavy, ATF, and diesel are extracted and the unconverted VGO is sent to vacuum
distillation where further diesel is extracted from side cut. Then the unconverted VGO goes to the
Furnace for further heating to 367℃ and through Reactor 2 for further cracking. Cracked material passes
through separators to remove lighter components and then is finally flashed the Fractionating column.

Following reactions takes place during the process:-

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4) FCCU (Fluidized Catalyzed Cracking Unit)

In cracking, large molecules are decomposed into small lower boiling molecules. More stable molecules
have the system as cracked gasoline and reactive ones polymerize forming fuel oil and even coke.

Catalytic Cracking has the following advantages over thermal cracking:

• Catalytic cracking gives more stable products.

• Catalytic cracking gives high-Octane gasoline.

Feed: The feed to the unit consists of Treated Vacuum Gas Oil from VGO-HDT Unit.

Primary products from this unit include Light Naphtha, Heavy Naphtha, Light Cycle Oil (LCO), Heavy
Cycle Oil (HCO), Fuel Gas, and LPG.

Fluidized Catalytic Cracking Unit consists of 2 sections:

1. Catalyst Section
2. Fractionation Section

Catalyst Section:

The Treated VGO feed from the feed surge drum enters the Preheat furnace where it achieves the

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temperature of 360℃. Fresh feed and recycle streams, known as Combined feed then goes to Reactor
Riser. The Catalyst Section consists of the Reactor and Regenerator, which, together with the Stand Pipes
and Riser, form the “Catalyst Circulation System”. The catalyst circulates up the Riser to the Reactor,
down through the Stripper to the Regenerator across the Regenerator Standpipe through Spent Catalyst
Slide Valve (SCSV), and back to the Riser through Regenerated Catalyst Slide Valve (RCSV).

Combined Feed is vaporized and heated to the reactor temperature by the hot catalyst. This mixture of
oil vapor and catalyst travels up the Riser into the Reactor. The gas oil commences cracking immediately
when it contacts the hot catalyst in the Riser and continues until the oil vapors are disengaged from the
catalyst in the Reactor. The cracked products in the vapour phase goes from Reactor to the fractionator’s
through Reactor Vapour line. Catalyst descending from reactor passes through Stripper, which surrounds
upper portion of riser. Catalyst flows over baffles counter current to rising stripping steam, steam
displaces oil vapour from catalyst particles and return these vapours to reactor.

Regenerator:

Coke is deposited on the circulating catalyst in the reaction zone, which reduces the active surfaces of
the catalyst. To regenerate the catalyst, coke is burnt off by air in regenerator. Atmospheric air is taken
through the main air blower at ambient conditions and discharged to regenerator at 220-250oC. The heat
of combustion raises the catalyst temperature to 640 –660oC range. This hot catalyst supplies heat to the
reactor. Regenerated catalyst leaves regenerator through regenerator standpipe. A slide valve called
Recycle Catalyst Slide Valve (RCSV) controls the temperature to the reactor. Regenerated Catalyst goes
to bottom of reactor riser and is lifted by lift steam.

Fractionation Section:

Cracked Oil vapours at around 500℃ from reactor top are fractioned into different cuts in this section.
Reactor vapours are fractionated into Heavy Naphtha, Light Cycle Oil (LCO),Heavy Cycle Oil (HCO)
and Clarified Oil (CLO).

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5) Diesel Hydrotreating Unit (DHDT)

The objective of the unit is to produce ultra-low sulphur diesel having less than or equal to10 ppm
sulphur along with cetane number improvement by at least 12 units over feed. Feed: The liquid feed to
DHDT is a mixture of straight run distillates and cracked feed stocks from FCC unit and DCU unit. Two
primary products from the unit consist of Stabilized diesel and Stabilized naphtha.

Hydrotreating and Saturation take place in 2 reactors (3 beds each) which are in series with the help of
NiMo and CoMo catalysts. Quenching is done with H2 gas to control the temperature of reactors, and
wash water is injected after the series of exchangers to prevent damage done by ammonium salts.

Liquid feed mixture (straight run distillates and cracked feed) are received in feed surge drum which
provides surge volume to even out fluctuations in feed entering the unit. The makeup gas and recycle gas
are combined with liquid oil feed and the total feed mixtureis heated in heat exchanger. Preheated oil
and hydrogen mixture is heated to the reactor inlet temperature in the reactor feed heater. The total feed
is then passed throughhydrotreating reactors. There are two reactors in series with each containing three
catalyst beds. Recycle hydrogen is used as quench gas for maintaining the desired weighted average bed
temperature (WABT) in each of the catalytic beds. The reactor effluent is cooled progressively in a series
of exchangers and finally in the Reactor Effluent Air Cooler before finally routing to the High-Pressure
Cold Separator. To avoid ammonium salt deposits and the risk of corrosion, wash water is injected at
the inlet ofthe Reactor Effluent Air Cooler.

After reactor effluent is cooled, it is sent to the HP (High pressure) Cold separator drum. The vapour phase
from this separator consists of recycle gas and quench gas and is circulated by a recycle compressor.
Recycled hydrogen stream leaving HP cold separatordrum is routed to HP Amine Absorber for hydrogen
sulphide (H2S) removal where lean MDEA absorbs H2S. Recycle gas is combined with makeup
hydrogen and gas oil feed to enter reactor circuits. The quench gas flows to the reactor bed. The
hydrocarbon/water separation obtained in this drum is not sharp and hence both hydrocarbon rich and
water rich streams are let down in MP(Medium Pressure) Cold separator for recovering a hydrogen rich-
off gas. This hydrogen rich gas containing H2S which leaves as an overhead product is routed to MP
Amine absorber. Sour water is separated from the hydrocarbon liquid phase in the water boot.

The hydrocarbon liquid flows to stripping section. Diesel Stripper fractionates the diesel product from the
reactor effluent liquid stream which is supplied from MP Cold separator. Stripper strips H2S and lighter
ends using MP steam to produce diesel product. The sour gas-off product from stripper reflux drum is sent
to LP Amine absorber. The water condensate containing dissolved H2S and traces of NH3 is removed from

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stripper reflux drum in its water boot. Wild Naphtha from stripper overhead is sent to stabilizer. It is
combined with stripper naphtha from Diesel hydro- desulphurisation (DHDS) unit and total naphtha feed
is stabilized and H2S is stripped in stabilizer. Off gas product from stabilizer reflux drum containing H2S,
butanes and lighter components is sent for amine scrubbing to LP Amine Absorber. The Stabilized naphtha
product is then cooled and sent to storage. The stripped wet diesel product is cooled. The dissolved water
in diesel product settles out as free water as product stream is cooled. The entrained water is removed in
coalescer and salt dryers before diesel product is routed for storage.

6) ISOMERIZATION (ISOM)

Isomerization is the process in which light straight chain paraffins of low RON (C6, C5and C4) are
transformed with proper catalyst into branched chains with the same carbon number and high-octane
numbers. Light naphtha C5 - 80 °C (C5 - 180 F) is used as a feed to the isomerization unit. Gasoline
specifications require a very low value of benzene due to its carcinogenic effect. Isomerization is one
of the best light naphtha octane boosting process for meeting the new gasoline specifications:

✓ Upto 91-92 RON

✓ Olefin free
✓ Sulfur free
✓ Aromatics free

The purpose of Isomerization process is to increase the octane number of the light Gasoline Brief
Process Description:

The feed for this unit is SRN (Straight Run Naphtha) and cracked naphtha from the FCC unit. This feed
passes through naphtha splitters as the main key component to be formed is i-C5 (isopentane).
Isopentane has a RON (Research Octane Number) of 93. This naphtha is hydrotreated to remove
impurities.
The main Isomerization reaction happens in the PENEX reactors which consist of catalystbeds based on
platinum.

ISOM unit can be divided into two parts:

1. NHT (Naphtha Hydro-Treating) section

2. PENEX section

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Naphtha Hydrotreating Unit (NHTU):
Feed to this section is taken is NHT FSD. Then it is pumped and preheated using producteffluent heat
exchanger1 and then sent to charge heater (i.e. furnace). Charge heater COT (Coil Outer Temperature)
is maintained between 315o C to 370o C, since above thisrange thermal cracking of feed may take place.
H2 from MUC (Make up Gas Compressor) is injected at the former pump discharge. This heated charge
enters the Hydrotreating Reactor where hydrogenation takes place. In this reactor, reactions like
desulfurization, denitrification & olefin saturation take place.
Long chains tend to break on higher pressures and temperatures, in this case if C7 is present in may
crack to C3 & C4. The reactor has 4 packed bed with Co-Mo based catalyst for hydrogenation. High
pressure of reactor is maintained at 40kg/cm2 to ensure reaction takes place in forward direction. This
pressure is maintained by adjusting the partial pressure of H2 from MUC.

The following reactions the place in hydrotreater

The treated output cools down using the product – effluent heat exchanger1 and further cooled using cold
water cooler. This cooled output enters a Cold Separator which is pressurized at 36kg/cm2.Separator top
routes the gas in the separator (contains mainly H2) to the Recycle Gas Compressor. This separator
collects the sour water in its boot and then it is sent to SRU (Sulfur Recovery Unit).The liquid
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hydrocarbons are then sent to a stripper column. The lighter gases are stripped due to bottom reboiling
using HP steam.

PENEX Section:
Feed from the NHT section is taken into FSD and then are passed through Dryers as moisture is
extremely harmful for the Pt based PENEX catalyst. Dried H2 is mixed withthe feed along with
perchloro – ethane and is fed to the PENEX reactors. 2 reactors filled with PENEX catalyst are set up in
series. The main isomerization reactions take place in these reactors and the output is a combination of
different isomers.
The product from PENEX reactors are then sent to a stabilizer where lighter gases (consisting FG &
LPG) are moved through scrubber. Scrubbing includes amine as well ascaustic scrubbing. The
stabilized bottom (having RON 83 – 84) is route.
isohexanenizer where isohexanes are absorbed while the rest which contain i-C5, DMB,n- C5, etc are
sent to rundown as ‘Isomerate’

7) Sulphur Recovery Unit (SRU)

AIM: To reduce the Sulphur content to 10 ppm or less.

H2S stream from all the units of refinery come to SRU and then Sulphur and amine are recovered.

Firstly oxidation reaction takes place where H2S is introduced to the horizontal furnace at around 1300
degree temperature. Thus SO2, SO3 are formed which is again treated with H2S forming Sulphur. Now
with the help of 2 close reactors having alumina-based catalyst S is liquefied and removed by the heat
exchanger.

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Then it is Absorbed and desorbed with Amine and finally sent to ARU for Amine Recovery.

8) CETP (Central Effluent Treatment Plant)

AIM: To recover oil from water and to treat all the waste water generated in refinery. This unit also helps
to reduce consumption of fresh water as the treated water can be again used in the processes

Most crucial part of refinery as it can’t be taken into shutdown due to its continuous operating procedure.
At different stages different devices, equipment are set up to recover every minute oil for example, Surge
sump, TPI, agitators etc.

The treatment starts with the removal of top layer of oil one stage Dissolved Air Flotation is also
introduced in our system to separate oily sludge from our stream. We alsointroduce packing of biomass
containing bacteria in bio-tower to reduce oil content and

ammonia from water. After passing through all the steps finally our recovered oil is sentback to unit
and water after passing through activated carbon filter is sent to RO plant.

The effluent treatment process in CETP has briefly four sections as follows:
1. Physical section: Here physical methods of separations are used to removelarge quantities of
oils and heavy sludge from water.
2. Chemical section: In this section, impurities such as dissolved and suspendedsolids are
removed by chemical methods of flocculation and flotation.
3. Biological section: This section deals with reducing organic matter in the effluent water and
this controlling its Biological/Chemical Oxygen Demand (BOD/COD).
4. Filters: Sand and carbon filters separate any remaining solids to have treated water
parameters within treatment specifications.

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METHYL TERTIARY BUTYL ETHER (MTBE)

INTRODUCTION

Indian Oil Corporation Ltd., Gujarat Refinery has set up 37,000 TPA MTBE (Methyl

Tertiary Butyl Ether) plant and has been commissioned In September 1999. The

objective of putting up the MTBE unit is to produce MTBE for blending into gasoline for

octane enhancement as well as increasing the oxygen content as required by future

statutory regulations.

The Operating Manual for the MTBE Process Unit provides information to supervisory

& operating personnel about plant systems and unit operating procedures.

The process licensor for the Unit is M/s. CATALYTIC DISTILLATIONS HOUSTON, TEXAS.

The MTBE unit consists of seven major sections: -

— C3/C4 Fractionation
— Feed Water Wash
— Primary Reactors
— CD Reaction Column
— Methanol Extraction Column
— Methanol Recovery Column
— Lights Column

The feed consisting of Hydrocarbon feed and Methanol is fed to the MTBE Section from

storage to form MTBE.

Cracked LPG ex FCC unit is the feedstock. And methanol is procured from G.N.F.C Bharuch, a nearby
Industry.

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MTBE FLOW DIAGRAM:-

PROCESS DESCRIPTION:-

C3/C4 FRACTIONATION

Feed Surge Drum, receives the hydrocarbon feed from Outside Battery Limit (OSBL) on V-1 level control.
The C3/C4 hydrocarbon is fed to tray No. 33 in the C3/Ca Splitter by C3/C4 Feed Pumps through Ca/Ca
Splitter Feed Bottom Exchanger.

The C3 s and lighter components in the feed vary from about 17 weight percent to about 38 wt%. Tray
No.33 is the optimal feed tray location. The Splitter is designed to achieve 1 wt % of total C3 s in the bottom
product and 1 wt% percent of C4 s and heavier in the C3 product.
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The C3/Q Splitter Feed / Bottom Exchanger, preheats the feed to 64°C. A total of 50 valve trays is used to
achieve the required fractionation. Column overhead vapour is condensed against cooling water in C3 / C4
Splitter condenser. The C3 product is further subcooled to 40°C in C3 Product Cooler and sent to OSBL for
storage. The Splitter Reboiler is provided by low pressure steam. The Q product is cooled to 40‘C in the
C3/C3 Splitter Feed/ Bottoms Exchanger before being charged to the Water Wash column.

FEED WATER WASH

The bottom product from C3/C4 Splitter is fed below, the bottom packed bed in the Water Wash Column
where it is washed with a counter current stream of demineralized water to remove catalyst poisons such as
acetonitrile, metal ions, and other basic nitrogen compounds. The washed C3 stream containing about 1
ppmw acetonitrile is fed to the C4 Feed Coalescer Drum. The C4 Coalescer Drum has a coalescer pad which
provides additional protection against water carryover. The washed C3 is filtered through Ca Feed Filters
before being mixed with the Methanol feed stream.

The Water Wash Column consists of two packed beds. Each bed is 7.8m high and is packed with a random
packing of 2" stainless steel pail rings. The water feed rate is at least 20 wt% of the design feed rate of the
hydrocarbon. Wash water from OSBL is fed to the Wash Water Break Drum. The wash water is
Demineralized Water which has a pH of about 7.5 to 9. The DM water from Wash Break Drum is pumped
by DM Water Booster Pumps to the Wash Water Column on flow control. Temperatures higher than 40°C
adversely impact the efficiency of acetonitrile removal and increase hydrocarbon losses in the effluent
water. The effluent water is degassed in the Water Degasser Drum then discharged to the Oily Water Sewer.
This waste water typically contains 200-250 ppmw acetonitrile and 0.06 wt% hydrocarbon.

PRIMARY REACTION (REACTOR no.1)

Fresh Methanol from the tank farm area is pumped by Methanol Feed Pumps to the Methanol Surge Drum
on level control. Before being fed to the surge drum it is mixed with re-cycled Methanol from the Methanol
Recovery section. About 2.0 m3/hr of Methanol is circulated back to the pump suction continuously based
on pump vendor requirements. The mixed Methanol from is pumped by Methanol Feed Pumps through the
Methanol Filters and then through the Methanol Guard Beds to remove foreign particles and catalyst
poisons. The Methanol stream is combined with the washed C4 stream. The two streams are mixed on ratio

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control. The C4/Methanol mixture is then fed to Reactor No.1 if necessary, the C4/Methanol mixture can be
preheated by the Medium Pressure (MP) steam in the Reactor No.1 Feed Heater. The normal inlet
temperature to Reactor No.1 is 40°C for Starts-of-Run and 65°C for End-of-Run operation. The feed enters
Reactor No.1 where MTBE and a limited quantity of by-products are formed. Under normal operating
conditions, ninety (90) percent of lsobutene conversion takes place in Reactor No.1. A temperature gradient
across the reactor results from the exothermic MTBE reaction. Vaporisation of the reactor contents limits
the temperature rise. The CD Reaction column overhead pressure controls the pressure of the reactor system.
The expected percent vaporisation is between 5-10 weight percent. A Johnson Screen, provided on the outlet
of the reactor prevents the catalyst migration to the CD Reaction Column and downstream equipment.

PRIMARY REACTION (REACTOR no. 2)

The effluent from Reactor No.1 is condensed I cooled against cooling water in Reactor No.2 Feed Cooler
and then fed to Reactor No.2 . The normal inlet temperature to Reactor No.2 is 50°C for Start of Run (SOR)
condition and 65°C for End of Run (EOR) condition. This temperature is controlled by bypassing a slip
stream around if necessary.

About 60% of Reactor No.2 feed lsobutene conversion takes place in this reactor. The actual percent
conversion of the lsobutene in each of the two reactors depends on the condition / "age” of the catalyst. The
total percent conversion in the two reactors combined is expected to be about 96%.

CATALYTIC DISTILLATION

The effluent from Reactor No. 2 is preheated to 67°C (SOR) and 78°C (EOR) against CD Reaction Column
bottom product in the CD Reaction Column Feed / Bottoms Exchanger and then fed directly to the CD
Reaction Column. lsobutene conversion is completed in the reaction column. A total of twelve beds packed
with CDTECH proprietary catalyst "bales" is provided in this design. The expected conversion across the
CD Reaction Column is 97.5% of the lsobutene in the teed to the column.

The amount of Methanol carried overhead in the CD Reaction Column is limited by the azeotropic
composition at 4 weight percent Methanol in C4 hydrocarbons. If methanol in feed is not sufficient to meet
the stoichiometric requirement of the reaction and methanol carried over in distillate. Than secondary

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Methanol feed is directly injected to the reaction zone on flow control reset by an online Methanol analyser
I controller. Three alternate locations for the secondary Methanol injection have been provided.

The overhead vapour is condensed against cooling water in the CD Reaction Column Condenser. Distillate
flows to the CD Reaction Column Overhead Drum and is pumped via the CD Reaction Column Reflux
Pump to the column as reflux. A part of discharge is fed to the Methanol Extraction Column through the
Feed Cooler. Non condensable if present are vented to the flare.

Medium pressure (MP) steam supplies the heat to reboils the column bottoms in the CD Reaction column
Reboiler. The steam is on flow control reset by the temperature on tray No. 12. MTBE product from the
bottom of the Reaction Column flows to the CD Reaction Column Bottoms / Feed Exchanger where heat is
recovered by heating the Reactor No.2 effluent. Further cooling to battery limit temperature (40°C) is
achieved in the MTBE. Product Cooler against cooling water.

METHANOL EXTRACTION

The Methanol Extraction Column Feed Cooler cools the CD Column distillate product to 40°C before the
distillate is fed to the Methanol extraction column. Counter-current contact with water recycled from the
Methanol Recovery Column extracts the Methanol from the distillate. The extraction occurs across two
packed beds. Each bed is randomly packed with 2" stainless steel pall rings 5.15m high. The hydrocarbon
effluent leaves the top of the Extraction Column to feed the Lights Column under pressure control. The
water-Methanol mixture leaves the bottom of the Extraction Column on flow control reset by the interface
level in the top section of the column.

The Recycle water is a closed circulation system between Methanol Extraction Column and Methanol
Recovery Column. Recycle water from the Methanol Recovery column Feed / Bottoms Exchanger heats
the Methanol and water from the Methanol Extraction column to 76°C. The recycle water is further cooled
to 40°C in the Recycle Water Cooler against cooling water prior to being fed to the Methanol Extraction
Column.

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METHANOL RECOVERY

The Methanol Recovery Column utilises four packed beds. Each bed is randomly packed with 1” metal
stainless steel pall rings. Each of the two packed beds above the feed point is 3.66m high and the two beds
below the feed are 3.1m high. Medium pressure steam provides heat in the Methanol Recovery column
Reboiler. Water exits the bottom of the column for recycle to the Methanol Extraction Column, via the
Methanol Recovery Column Bottoms Pump. The overhead vapour is condensed against cooling water in
the Methanol Recovery Column Condenser. Condensate collects in the Methanol Recovery Column
Overhead Drum. The Methanol Recovery Column Reflux Pump transfers recovered Methanol to the column
as reflux. The net overhead from the Methanol Recovery Column is cooled to 40°C against cooling water
in the Recycle Methanol Cooler and then recycled to the Methanol Surge Drum.

To limit fouling the column bottoms are purged once every two weeks until the low liquid level in the
column bottom sump is reached. The water is purged by the operator observing the level in the sump of the
Methanol Recovery Column. The purged water is sent via the OWS to wastewater treatment for disposal.
The purged water under normal operating conditions contains about 25 ppm Methanol (max.). Make-up
water (demineralized) from OSBL is also hand controlled by the Operator watching the liquid level in the
sump of the column. Water accumulates in the Methanol Recovery Section due to dissolved water in the Q
feed from the water wash column and production of water by side reactions. A portion of the water is
removed from the unit by the saturated C4 raffinate. Accumulation exits the system by the periodic purge
to the waste treatment via OWS.

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FOOD GRADE HEXANE (FGH)

INTRODUCTION

Food Grade Hexane (FGH) is a petroleum fraction having a boiling range of 63-70°C. In India, nearly 95% of the
FGH consumption is for the solvent extraction of oil bearing seeds, cakes and brans to produce edible oil. Market
analysis indicates that nearly 35% of PGH consumption is in the three states viz. Gujarat, Madhya Pradesh and
Rajasthan. Moreover, the increasing oil seed production has contributed to a spurt in FGH consumption over the
years and demand estimates indicates a deficit of about 7000 MT in 1992-93, about 20,000 MT in 1993-94 and
30,000 MT in 1994-95 on all India basis.

The FGH plant at Gujarat Refinery was designed by M/s EIL of India and plant was commissioned in September
1995. The design capacity of the plant is 1,00,000 MTPA.

The FGH plant is having a capacity to produce 28,000 MTPA of FGH with a blend of UDEX Raffinate and lBP-
70/ Light Naphtha as the feed stock. ISOM DIH is being used as feedstock for FGH Unit, since Jan-2016. The
plant was revamped by installing hydrogenation reactor in place of Clay Tower to reduce maximum Benzene
concentration in FGH from 1% to 0.2% by vol. Hydrogenation Technology was developed by ICC R& D and
EIL Plant was commissioned with hydrogenation reactor in May, 2001. Afterwards Gujarat refinery produces
WHO grade and Polymer grade hexane.

Currently, Clay Towers, Hydrogenation section and Rerun column is not in use and kept as redundant.

The common uses of FGH are:

— Solvent for oil seed extraction.

— Glues and Adhesives for production of foot wear
— Medium for various polymerization reactions in industries like Pharmaceuticals,
lacquers, printing ink.
— Retreading of car tyres etc.
— PGH is used as co-polymer and supplied to Panipat Refinery.

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BRIEF DESCRIPTION:

A fractionating column or fractionation column is an essential item used in the distillation of liquid mixtures so
as to separate the mixture into its component parts, or fractions, based on the differences in their volatilities.

In refineries, the crude oil feedstock is a very complex multicomponent mixture that must be separated and yields
of pure chemical compounds are not expected, only groups of compounds within a relatively small range of
boiling points, also called fractions and that is the origin of the name fractional distillation or fractionation.

In FGH Unit a heartcut Hexane stream (GS-70°C) is obtained by operating two distillation columns in series in
the fractionation section which is hydrotreated to reduce unsaturates and Benzene to the specification levels. The
plant is designed to produce Food Grade Hexane from feed consisting of Udex Raffinate (70,000 TPA) and
straight run naphtha / light naphtha (30,000 TPA). Currently, ISOM DIH is being used as feedstock for FGH Unit
from Jan-2016 for producing Poly Grade Hexane.

The process can be broadly classified into three sections:

— Fractionation section.
— Hydro treating section (kept bypassed since Jan-2018)
— Rerun section. (kept bypassed since Jan-2018)

The rerun section removes light and heavy contaminants from hydro treated

stream to yield finished product.

PROCESS DESCRIPTION

FRACTIONATION SECTION:

Feed to the fractionation section consists of Udex Raffinate and IBP-7O from AU-l or light naphtha from hydro
cracker. ISOM DIH is being used as FGH feed from Jan-2016. To increase rundown purity, some part of FGH
rundown is also recycled back to FGH feed surge drum V-S, as per requirement. Recycle is being done through
UDEX Raffinate line via Udex Raffinate flow control valve, which was redundant after shutdown of UDEX Unit
in Dec-2016. This line is being utilized as recycle line from May-2019. Udex Raffinate comes from UDEX

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Raffinate storage and is pumped to the feed surge drum by Raffinate feed pump under level control of feed surge
drum.

Naphtha comes directly from AU-I / Hydro cracker under flow control. Depentaniser feed pump, pumps the feed
under flow control to the Depentaniser after heat gain in the feed pre heater, by heat exchange with bottoms.

Feed enters the 20th tray and alternate feed entries are provided in 24th and 16th tray to handle variations in feed
composition. Distillates from C-01 consists of lighter which are condensed by the depentaniser condenser and
collected in the reflux drum. Part of distillates are pumped by reflux pump to C-01 as reflux under flow control
and rest goes to balanced Naphtha cooler under level control of reflux drum.

Feed enters the hexane column C-02 in 32"0 tray. Provision is there for alternate Feed locations to take into
account variations in feed compositions. The distillates consist of raw hexane which is condensed by hexane O/H
condenser and collected in reflux drum. A part of the raw hexane is pumped by the reflux pump back to
C-02 as reflux under flow control cascaded to a temperature controller on tray no.48 of C-02 and the rest is sent
to raw hexane surge drum. There is a provision for cooling the raw hexane before it enters hexane surge drum via
raw hexane cooler. This is by passed during normal operation.

Bottom of C-02 goes to balance naphtha cooler after giving up heat in feed preheater.

Both C-01 top and C-02 bottom streams leave the unit as balance naphtha product.

C-01 and C-02 columns are under split range pressure control by hot vapour bypass of over head vapours to their
respective reflux drums.

Heat to the columns is provided by thermosiphon reboilers using MP steam and controlled by flow controllers
cascaded to either temperature controllers on 3rd tray from bottom of column or reboiler return stream to column.
The condensate from each reboiler go to their respective condensate pots, from where they leave the unit under
level control of condensate pots.

PRODUCTION OF N-PENTANE IN FGH UNIT:

The process of LAB (Linear Alkyl Benzene) production needs n-pentane (more than 95% volume purity) as one
of the solvent. N-Pentane is highly valued product and

is required by all LAB producers. A preliminary study was already carried out to check the feasibility of producing
N-Pentane from K8 top ex-Aul. The process of n-Pentane production in brief is given below:
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The feed top Au-l is fed to the column C-01 after preheating to 70 Deg. C-01 bottom, which will be rich in hexane,
is cooled in Eli-12 and cooler 85-10 and will be routed to balance naphtha.

C-01 overhead stream which will be mixture of N-Pentane and ISO Pentane will be fed to C-02 column for further
fractionation. The top product from 002 column is rich in ISO-Pentane (approx. 62% vol.) and is routed to balance
naphtha.

The bottom product is n-Pentane with more than 95% Vol. Purity is stored in bullet No.44 in PDF after cooling.
Sample is collected from outlet of FGH R/D cooler near FGH R/D.

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VIS-BREAKER UNIT (VBU)

INTRODUCTION

The Vis-breaker Unit was originally designed to process 1.0 MMTPA of atmospheric residue, vacuum gas oil
and vacuum residue from a 50:50 blend of Light Arabian and North Rumaila crudes for the production of fuel oil.
In the year 1993, the unit was revamped with introduction of soaker technology for increasing its capacity from
1.0 MMTPA to 1.6 MMTPA using 100% North Gujarat or Imported Crude vacuum residue as feed stock for the
production of fuel oil. As per requirement, fuel oil is also produced by using vacuum residue as feed stock and
then adding cutter stock.

In conventional coil cracking, the residence time in the coil is less, hence the desired conversion is achieved by
maintaining higher (470 OC or more) cracking temperature. However, in soaker technology, the same amount of
conversion is achieved at much lower temperature (455 OC or less) by providing adequate residence time at its
cracking temperature in the Soaker Drum.

Cracking starts in the heater coils and this cracking reaction is allowed to continue in the soaker drum. Thus
both temperature and residence time are very much important for achieving desired degree of conversion.

At the outlet of soaker, a back pressure control valve maintains sufficient back pressure (about 12.0 kg/sq.cm)
in the soaker drum and in the heater coils so that the reaction mixture remains in the liquid phase and thus helps
in maintaining adequate residence time for desired conversion. The unit is designed for normal conversion of 5.7
wt% of feed with the production of stable fuel oil.

Excess conversion results in instability in the fuel oil and viscosity starts increasing. Instability occurs due to
separation of asphalteness. In the soaker Vis-breaker, since cracking temperature is maintained lower as
compared to that of coil cracking, the rate of coke deposition in the heater coils is less and fuel consumption is
also less. The unit consists of two pass cracking heater, soaker and a fractionator. The products of the units are
fuel oil, VB gas oil, VB Naphtha and fuel gas.

FEED AND ITS SPECIFICATIONS

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 Atmospheric Residue

 Vacuum Gas Oil

 Vacuum Residue from a 50:50 blend of Light Arabian and North Rumaila

Sr. Specification North Imported Bombay North Imported

No. VR High VR RCO
Gujarat Gujarat
VR
RCO

1 Specific Gravity 0.994 1.029 1.015 0.940 0.973

2 Pour Point (OC +54 +54 +78 +39 +15

˚)

3 Sulphur (wt %) 0.29 5.13 0.77 0.19 3.91

4 Kinematic 1540 2524 1396 63.5 74

Viscosity at 100
O
C (cst)

5 Wax content 22.3 - - - -

PRODUCTS

 Fuel Gas

 VB Naphtha

 VB Gas Oil

 VB Tar

UTILITIES AND THEIR CHARACTERISTICS

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The pressure and temperature of the utilities at the battery limit of the unit are:

Sr. Description Pressure Temperature ( OC )

No. (kg/sq.cm)

1 LP Steam 4.5 165

2 MP Steam 10.0 230

3 Re-circulating water 5.5/3.5 33/45

supply/return

4 Boiler feed water 22.5 190

5 Fuel Oil 10.0 80-271

6 Fuel Gas 3.1 35-50

7 Service water 3.5 Ambient

8 Service air 7.0 Ambient

9 Instrument air 7.5 Ambient

10 Flushing oil 8.0 40

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PROCESS FLOW DIAGRAM

PROCESS DESCRIPTION

The various components of the feed are first preheated in the heat exchanger to about 150 OC and then received
in the surge drum. The combined feed stock is pumped by the Vis-breaker charge pump in to the heat exchanger
set to about 315 booster pump and the feed suction goes to the suction of the charge. The hot feed from the
discharge of the booster pump is routed to the two passes of the Vis-breaker furnace under flow control. The VB
furnace provides the heat required for preheating and cracking reactions of the feed is heated upto 445 OC.

At the furnace outlet, feed enters the soaker drum from the bottom and comes down from the top. In the soaker
drum, cracking reactions are allowed to continue at its cracking temperature by providing residence time of about
20 minutes for the desired conversion. At soaker outlet, one back pressure controller maintains a constant back
pressure of about 12.0 kg/sq.cm in the soaker and in the heating coils so that the reaction mixture remains in the
liquid phase and thereby increases its residence time for better conversion. The hot reaction mixture at the soaker
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outlet is quenched by injecting cooled Visbreaker tar to about 388f OC or arresting further cracking reactions. The
quenched effluent from the soaker outlet enters the VB fractionator where it is separated into various products.

In the bottom of the VB fractionator, steam is introduced to remove lighter fractions. As and when required,
slop oil from GRE tanks is also fed to VB fractionator along with gas oil in the transfer line for stripping out the
light ends. VB tar is removed as bottom product. The bottom product goes to the fuel oil tank or LSHS (Low
Sulphur Heavy Stock) tank depending upon the feed quality. One side draw i.e VB gas oil can be routed to HSD,
LDO, DHDS or LSHS. However it is normally routed to LDO/DHDS.

To maintain the thermal condition of the column and heat recovery, one gas oil circulating reflux has been
provided. The overheads from the VB fractionator are VB Naphtha and gas.

Gas is sent to the fuel gas network. Naphtha is stabilized in a debutanizer and is sent to the Naphtha Merox Unit
for removal of the sulphur compounds and finally to storage.

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BITUMEN BLOWING UNIT (BBU)

INTRODUCTION

The Bitumen Blowing Unit (BBU) under Gujarat Refinery Expansion was designed to process Vacuum residue
obtained from 50:50 blend of North Rumaila and Light Arabian crudes to process 200,000 metric tones per year of
80/100 pen, 25,000 metric tones per year of 60/70 pen and 25,000 metric tones of 30/40 pen bitumen product. The
unit was designed to operate in blocked out operation to produce the above three grades of bitumen.

The major equipments of Bitumen Unit are located in the Vacuum Unit plot area and a no. of common utility
systems serve both these units. The chief advantage of the Biturox process is the flexibility in the feed stock that
can be used for the production, a wide range of other materials like Propane de-asphalted and Vis-breaker residues
blended with vacuum gas oil/extract can be used in a proper blending rate.

The biturox unit is designed for continuous operation and the capacity range of the unit covers 60-100% of the
designed capacity.

FEED AND ITS SPECIFICATIONS

Persian Gulf crude or a mixture of Persian Gulf and North Gujarat crude will be used as feed stock. As design
feed, the mixture of Persian Gulf and North Gujarat crude was selected for the design of the Biturox Reactor. A
longer retention time was required for the production of S65 using vacuum residue from the mixture of Persian
Gulf and North Gujarat crude.

Sr. Specification Unit VR Persian VR Persian

No. Gulf crude
Gulf/North Gujarat crude

1 Penetration index mm/10 155 234

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2 Softening point ˚ OC 40.5 41.0

3 Specific gravity 1.0198 0.9995

4 Density at 15 OC Kg/cu.dm 1.0259 1.0056

5 Flash Point ˚ OC 320 316

PRODUCT AND ITS SPECIFICATIONS

The product obtained is three grades of bitumen.

 S90 grade bitumen ------------------- 99% yield

 S65 grade bitumen ---------------- -- 98.5% yield

 S35 grade bitumen ---------------- -- 97.5% yield

Sr. No. Specification Unit S90 grade S65 grade S35 grade

1 Specific gravity 0.99 0.99 0.98

2 Water content wt% 0.2 0.2 0.2

3 Flash point ˚ OC 175 175 175

4 Softening Point ˚ OC 35-50 40-55 50-65

5 Penetration index mm/10 80-100 60-70 30-40

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UTILITIES AND ITS CHARACTERISTICS

Sr. No. Utility Temperature (˚ OC) Pressure

(kg/sq.cm)

1 LP steam 151 4.0

2 MP steam 230 10.0

3 Boiler feed water 105 14.5

4 Fuel gas 35-50 1.7-2.1

5 Fuel oil 80-271 10.4

6 Tempered water 65-85 5.0

7 Circulating cooling water 33/45 4.5/2.5

8 Supply/Return service water Ambient 2.5

9 Instrument Air Ambient 7.0

PROCESS DESCRIPTION

The unit shall receive hot feed (vacuum residue) from the vacuum unit directly at a temperature of about 240 ˚
O
C and cold feed from storage. When vacuum unit is shutdown, bitumen unit will receive the entire feed from
storage at 120 ˚ OC.

The feed enters the converter at a temperature of 240 ˚ OC. This is achieved by heating the feed in the heater.
The vacuum residue is blown by air in the biturox reactor at temperature of around 240 ˚ OC. Since this is an
exothermic reaction, the evolved heat is to be removed. This is accomplished by injecting water along with
Process air and steam into the reactor at the top. The blown bitumen is pumped from the Biturox reactor under
level control through the steam generator and the bitumen product rundown cooler.

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The hydrocarbon vapours, steam and the unreacted air from the reactor overhead go to the water quench drum
where hydrocarbons are condensed along with some water. The uncondensed gas is burnt in the incinerator
through the water seal drum. The condensed hydrocarbons and the water are separated in the settling drum from
where the oil is routed to slops and the water drained to oily sewer.

PROCESS VARIABLES

1. Temperature

As the process is an exothermic one, it is important, that the operating temperature within the reactor will be
tightly controlled. This is accomplished by injecting of process water into the air pipes. As the water vapourizes
in the air pipes, it cools the content of the reactor making it possible to maintain precise temperature control.

In principle the temperature in the vapour space of the reactor is at least 50 OC less than the bitumen temperature
in normal operation.

In case of high temperature in the vapour space, low-pressure steam can be fed into the vapour space for
quenching purposes. The quench steam valve is operated by hand and approached from the ground surface at the
steam header of the reactor.

2. Pressure

To prevent an over pressure of the reactor, a rupture disc in combination with safety valve at the top of the
reactor is provided.

The set pressure of the safety valve is related to the design pressure of the reactor. The set pressure of the
rupture disc is lower than the set pressure of the safety valve, so that it will be possible to adjust the correct
pressure after bursting of the rupture disc before the set pressure of the safety valve will be reached. The normal
operating pressure range ends at 90% of the bursting pressure of the rupture disc.

If this percentage is exceeded, the rupture disc will be damaged and may burst under the normal operating
pressure. The burst of the rupture disc is indicated by a pressure gauge with an alarm high signal, located between
rupture disc and the safety valve.

3. Liquid Level
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The level in the reactor is indicated and controlled by a liquid controller which affects the level valve in the
discharge line of the product. A redundant level control based on a measurement of a differential pressure of the
liquid column in the reactor is provided.

During operation four temperature transmitters, indicating important points of the liquid level, additionally
supervise the liquid level. The level indication is based on the temperature difference between the liquid and
gaseous phase

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OM&S ( OIL MOVEMENT & STORAGE)

This Unit handles transportation and Movement of products manufactured by the refinery.It has 2 sections
1. Receipt: Deals with monitoring and storage facility of tanks.

2. Dispatch: Deals with transportation of our finished products to designated locationsby

different means.

Under the dispatch section we have

1. TWL( Tanker wagon Loading) – MS, HSD, FO, LDO, SKO, Kero are transportedby Railway
Wagons. The products are transported through rack of wagons and eachrack consists 50 wagons

2. TTL( Truck and Tanker loading) – LAB, HSD, PGH, MTO are transported by trucksand tanks

3. LPG – By pipelines

4. Bitumen – By pipelines and Tanks and Truck Loading3 types of Bitumen are transported.

· VG 10 is the most soft bitumen

· VG 30 is of moderate hardness

· VG 40 is of best quality and hardest in all 3.

5. Petcoke --- Low Sulphur and high Sulphur are transported by truck and railways.Petcoke is
used in furnace, cement industry.

Under receipt Section:

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Tanks

There are 3 types of tanks

1. Fixed Roof are conical in shape and are for heavy products

2. Floating Roof for MS, ATF, and for lighter products.

3. Fixed cum Floating Roof for benzene, toluene and for other toxic products in MS blender
there are different parameters on which blending depend on

 Benzene content < 1%

 Density : 730-750

 Octane no. : 92-93

 Sulphur content : 3-4 ppm

 Vapour pressure :- 52-55

Different colors /dyes are added in MS in the quantity of around 3 ppm to give its characteristic color (
orange)

To ensure proper health for people working in the refinery and the people living in nearby regions, the
hazards due to refinery are monitored and minimized. The emission and effluent satisfy safe norms; there
are safety audits and health and emergency facilities. There is a health centre in refinery and a hospital in the
refinery township for medical service. Dedicated ambulances are present to address medical emergencies
in refinery. To ensure safety of employees and workers in refinery on personal level, there are safety
provisions and methods. People in refinery have to use PPE and there are work permits required for workers
to carry out maintenance and project work. It includes cold work permit, hot work for carrying out work
involving risk of fire such as welding, working on height permit, working in confined space permit, etc.
There is fire and safety department that maintains safety and deals with emergencies in refinery. The
vehicles inside refinery are comprehensively checked and have Electrostatic Precipitators (ESP) to prevent
sources of ignition through vehicle exhaust.

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REVERSE OSMOSIS PLANT

A) ULTRAFILTRATION-
Ultrafiltration is a pressure- driven process with semi permeable synthetic membranes to separate certain
chemicals and materials from water. Various membrane configurations are available for ultrafiltration. Some
are fibres or
tubes with the active membranes that are asymmetrical, being found on the inside while others are flat sheets
which can be stacked in frames or rolled in to spiral configuration.
When a cross- section is viewed under a high-magnification microscope, the pores appear
at one end of the membrane. The pores at the surface are so small that they will allow only water and small
dissolved chemicals to pass through, while stopping bigger molecules and particle. Due to the small pore size,
water will flow through the membrane only by applying pressure.
A build-up of contaminants at the surface of the membrane is prevented by operating the
system in a cross- flow mode. Here the flow is pumped parallel to the membrane surface which result in a
constant scouring action, sweeping particles away and back in to feed flow.
Cross flow filtration results in the division of one stream (feed) into others- a dirty water
stream which is known as reject and a clean water stream which is known as permeate.
A phenomenon of ultra-filtration is known as concentration polarization. This is a build-up
of chemical contaminants at the membrane surface as the water filters through to the other side. The condition is
not permanent and can be removed by flushing the membrane with either more dilute feed or with clean water,
or permeate.
Despite the asymmetric structure and cross flow operation, ultra-filtration membrane can
still become clogged as particles of a similar size are pushed into the pores, causing them to plug. Some
membrane configuration allow for back washing. This is a periodic reverse flow through the membrane from
the clean water side, back through to the feed water side. As the water is forced through the pores under high
pressure, it pushes out the contaminating particles back in to the feed stream and unplugs the pores.

Ultra-filtration membrane can be chemically cleaned to restore high clean water flow rates
and maintain separation performance.
One of the benefits of using ultra filtration is the quality of permeate produced. Ultra-
filtration can be used independently or in association with other treatment such as coagulation or precipitation.
It can be also used effectively as a method of pretreatment for osmosis. Its benefits range from producing a high
quality water stream for use or recycling to reducing waste volumes and recovering valuable materials from
waste streams.

B) REVERSE OSMOSIS-
The spontaneous flow of water from a dilute solution to a concentrated solution is called osmosis and when a
semi-permeable membrane separates these two solutions, by reversing the osmotic flow by applying a pressure
in excess of the osmotic pressure is called reverse-osmosis.
Reverse-osmosis is also a process of separation. The feed water stream is separated in to a
stream of purified water and a stream of concentrated solutes and particulate. This is compared to standard
filtration where the entire fed stream pass through the membrane pores, leaving the particulate embodied

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in the filter media.

C) REVERSE OSMOSIS PLANT PROCESS-

The process of the reverse osmosis plant happens by the following steps-
1) High rate solid contact clarifier (HRSCC)- Feed from the Chemical Treatment Effluent Plant (CETP)
enters the clarifier through the top. The flow rate of the feed entering the clarifier or in the clarifier is generally
940 m3/hr. In clarifier, big solid particles are settled at the bottom from the feed where the big particles are
separated from the feed. The big solid particles settled at the bottom are sent to the surge sump whereas the
remaining feed goes to the guard pond.

DIAGRAM OF CLARIFIER

2) Guard pond- Guard Ponds are “safeguard” mechanisms for preventing the discharge of
“untreated/abnormal” effluents of the feed into marine environment. From the guard pond, the feed goes in the
pressurized carbon filter (PSF).
3) Pressurized Sand Filter (PSF)- In a Pressure sand filter, feed (water) is gone through multi layers of filter
media comprising reviewed sand, rocks and rock layers. The contaminants in the water are caught in the media
bed and shifted water goes into the release manifold at the base of the tanks. The following step is discharging,
a procedure of adequately expulsion of caught contaminants from the media bed. After back washing, the filter
is flushed with raw water and after the required nature of water is accomplished the filter is returned to support.
From PSF the feed goes in Activated Carbon Filter (ACF).

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DIAGRAM OF PSF

4) Activated Carbon Filter (ACF)- In Activated Carbon Filter, feed is gone through multilayers of filter media
comprising big granules and carbon layer at the top. These are designed to remove free chlorine, organic matter,
odour and colour present in the feed. It operates through adsorption and here also after back washing, the filter
is flushed with raw water and after the required nature of water is accomplished the filter is returned to support.
From ACF, the feed is sent to ultrafiltration feed tank.

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DIAGRAM OF ACF

5) Ultrafiltration feed tank- The feed is stored in the UF feed tank that is further sent to the cartridge filter.

6) Cartridge filter- The pore diameter of the membrane of cartridge filter is 5 microns. These are used to
remove solid and other dirt particles from the feed. These filters are made up of polypropylene or cellulose.
When the water gets passed through this filter, the solid material gets trapped on the cartridge filter. The filters
are placed according to the size of the particles. This means that the filters are rated according to their ratings to
remove particles of a specific size.

These filters can remove sediments, metals, and other microorganisms from the water. From the cartridge filter,
the feed is sent to the oil polishing.

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DIAGRAM OF CARTRIDGE FILTER

7) Oil polishing - Oil polishing is used to separate oil from the feed. After oil polishing, the feed goes to the UF
skid.
8) Ultrafiltration skid- The pore diameter of the membrane of ultrafiltration skid is 0.001 microns. Here the
process of ultrafiltration takes place. The membranes operated by feeding the feed through the membrane
modules at a high velocity. The membrane pores are sized so that the dissolved solid particles present inside
the feed is retained on the inside of the membrane and the treated effluent is allowed to pass through the
membrane. 99% recovery of the product goes into

the UF skid. From the ultrafiltration skid, the feed is sent to the Reverse Osmosis (RO) feed tank.

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DIAGRAM OF ULTRAFILTRATION SKID

9) Reverse Osmosis Feed Tank- Feed from the UF skid is stored in the RO feed tank which is further sent to
cartridge filter.
10) Cartridge filter- There is also another cartridge filter after RO feed tank. The pore diameter of the
membrane of cartridge filter is 5 microns. These are used to remove solid and other dirt particles from the feed.
These filters are made up of polypropylene or cellulose. When the water gets passed through this filter, the solid
material gets trapped on the cartridge filter. The filters are placed according to the size of the particles. This
means that the filters are rated according to their ratings to remove particles of a specific size. These filters can
remove sediments, metals, and other microorganisms from the water. From the cartridge filter, the feed is sent
to the RO 1 (Reverse Osmosis 1) skid.

11) Reverse osmosis-1 skid- The flow rate of the feed here is 188 m3/hr. . The pore diameter of the membrane
of RO-1 skid is 0.001 microns. In RO-1 skid, there are two sections of feed, one is reject and the one is
permeate. Permeate is that part where all the clean water of the feed flows at the rate of 188 m3/hr whereas
reject is that part of the feed where all the dirty water (water containing dirt particles, some solid particles ,
waste) is there flowing at the rate of 62 m3/hr. The permeate goes into the RO-1 A feed tank whereas the reject
goes into the RO2 feed tank. The process of reverse osmosis is performed here where high concentration feed
(initial feed in RO-1 skid) is converted into low concentration feed (permeate) through semi permeable
membrane under pressure.

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RO SYSTEM SCHEMATIC DIAGRAM

12)Reverse osmosis-1 A feed tank- The permeate from the RO-1 skid comes into RO-1 A feed tank where it is
stored and further goes to RO -1 skid.

13) Reverse osmosis-1 A skid- The flow rate of the feed here is 190 m3/hr. Permeate of RO-1 skid is the initial
feed in the RO-1 A skid. The permeate here of RO-1 A skid containing clean water goes at a flow rate of 189
m3/hr into the Degaser from where it is stored in RO-1 A Permeate tank whereas the reject of the RO1 A skid
containing dirty water (i.e. water containing dirt particles, some solid particles, waste) at a flow rate of 21 m3/hr
is recycled to the RO feed plant.

90% of the recovered product goes into the RO-1 A skid.

14) Degasser - The permeate from the RO-1 A goes into the degasser. Degasser is a simple arrangement with a
packed tower having plastic rachig rings / pall rings, which enables the water flowing down breaks into droplets
due to the high surface area of the packing and releases the carbon dioxide. The air blown from the bottom
carries away the carbon dioxide through the vent on the top of the degasser. The Degassed water is stored below
in the tank which now goes into the RO-1 permeate tank.
15)RO-1 A Permeate tank- The Degassed water now is stored in this tank where it is now sent to de-
mineralized plant to remove or de- mineralize the degassed water.
16) RO-2 feed tank- The reject from the RO-1 skid goes into the RO-2 feed tank where it is stored and further
it goes to the RO-2 skid.
17) RO-2 skid- The reject from the RO-1 skid comes here at a flow rate of 150 m3/hr which is the initial feed
here. The permeate here of RO-2 skid containing clean water goes at a flow rate of 102m3/hr into the cooling
tower plant whereas the reject of the RO-2 skid at a flow rate of 48m3/hr goes at the endpit. 68% of the
recovered product goes into the RO-2 skid.

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Project-1

PROJECT OBJECTIVE: To determine the efficiency of furnace in Fluidized Catalytic Cracking Unit
(FCCU).

Furnace: An enclosed structure in which material can be heated to very high temperatures.

Types of furnace: Drafts are produced by the rising combustion gases in the stack, flue, or by mechanical
means. For example, a blower can be put into four categories: natural, induced, balanced, and forced.

Natural draft: When air or flue gases flow due to the difference in density of the hot flue gases and cooler
ambient gases. The difference in density creates a pressure differential that moves the hotter flue gases into the
cooler surroundings.

Forced draft: When air or flue gases are maintained above atmospheric pressure. Normally it is done with
the help of a forced draft fan.

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Induced draft: When air or flue gases flow under the effect of a gradually decreasing pressure below
atmospheric pressure. In this case, the system is said to operate under induced draft. The stacks (or chimneys)
provide sufficient natural draft to meet the low draft loss needs. In order to meet higher pressure differentials,
the stacks must simultaneously operate with draft fans.

Balanced draft: When the static pressure is equal to the atmospheric pressure, the system is referred to as
balanced draft. Draft is said to be zero in this system.

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IMPORTANCE:

For the proper and the optimized heat transfer from the flue gases to the boiler tubes draft holds a relatively high
amount of significance. The combustion rate of the flue gases and the amount of heat transfer to the boiler are
both dependent on the movement and motion of the flue gases. A boiler equipped with a combustion chamber
which has a strong current of air (draft) through the fuel bed will increase the rate of combustion. The stronger
movement will also increase the heat transfer rate from the flue gases to the boiler.

INDUCED FURNACE: An induction furnace is an electrical furnace in which the heat is applied by
induction heating of metal. Induction furnace capacities range from less than one kilogram to one hundred
tons, and are used to melt iron and steel, copper, aluminum, and precious metals.

WORKING PRINCIPLE OF INDUCTION FURNACE:

The principle of induction furnace is the Induction heating:

Induction heating is a form of non-contact heating for conductive materials.
The principle of induction heating is mainly based on two well-known physical phenomena:

1. Electromagnetic induction
2. The Joule effect

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1. ELECTROMAGNETIC INDUCTION: The energy transfer to the object to be heated occurs

by means of electromagnetic induction. Any electrically conductive material placed in a variable
magnetic field is the site of induced electric currents, called eddy currents, which will eventually lead to
joule heating.

2. JOULE HEATING:
Joule heating, also known as ohmic heating and resistive heating, is the process by which the passage of
an electric current through a conductor releases heat.
The heat produced is proportional to the square of the current multiplied by the electrical resistance.

Q ∝ I2 ⋅ R
Induction heating relies on the unique characteristics of radio frequency (RF) energy – that portion of
the electromagnetic spectrum below infrared and microwave energy. Since heat is transferred to the
product via electromagnetic waves, the part never comes into direct contact with any flame, and there is
no product contamination.
APPLICATIONS OF INDUCED FURNACE:

Here are five of the many applications that induction furnaces can be used for in your melting, heating, holding,
and pouring operations.

1. Investment casting. Induction melting is often used for investment casting because they come in a
wide variety of air and vacuum furnaces. These furnaces work great for nearly all metals.
2. Precious metals melting. Steel is precious for many, but induction furnaces can also be used to melt
precious metals such as platinum group metals. This allows them to be refined and used for jewelry
manufacturing.
3. Copper melting. Induction furnaces can be used to melt custom castings or casting large bronze
structures. They’re built to provide the melting you need for most copper applications with low metal loss
and precise temperature control.
4. Alloy manufacturing. Induction furnaces are popularly used in alloy manufacturing for optimal
uniformity and flexibility. Those in alloy manufacturing companies can count on induction furnaces to
provide them with the correct amount of induction stirring each and every time so every product comes out
exactly the same.

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5. Aluminum melting. Aluminum melting is another popular application used for induction melting.
Because induction furnaces are energy efficient, they’re considered optimal for converting alumina into
pure aluminum and then into aluminum alloys. This is because this process consumes a lot of energy and
so the more energy that can be saved the better.

ADVANTAGES OF INDUCED FURNACE:

 Improved process efficiency.

 Localized, constant and precise heating.
 Temperature control.
 Energy saving.
 Possibility of integration into production lines.
 Best quality and yield/performance.
 Pollution free, fast and secure technology.
 Improved working environment.

DISADVANTAGES OF INDUCED FURNACE:

 Cost of the equipment and the cost of the process are very high.
 Efficiency of heating is poor being less than 50% in many cases.
 Heating will be more in regions of the work piece closer to heating coil.

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FURNACE AT FCCU PLANT:

TAG NAME OF THE FURNACE: 820 - F1.

FEED INLET COMPOSITION: VACCUM GAS OIL (VGO) AT 313 TO 315.

FEED OUTLET CONDITIONS: VACCUM GAS OIL (VGO) AT 343 TO 350.

NUMBER OF PASSES: 2.

TUBE SIZE: 6’’.

TOTAL NUMBER OF BURNERS: 6.

PRESSURE @ GAS BURNER DESIGN (MAX) HEAT RELEASE, Kg/cm2(g): 1.41.

INDIVIDUAL BURNER DESIGN (MAX) HEAT RELEASE, 106 kcal/h : 2.43.

COMPOSITION OF FUEL GAS:

GASEOUS
FUEL :
Mole
S.No. Components
%
1 Hydrogen(H2) 20.14
2 Carbondioxide(CO2) 0.16
3 Oxygen(O2) 1.90
4 Nitrogen(N2) 24.61

5 Methane(CH4) 24.36

6 Ethane(C2H6) 8.92

7 Ethylene(C2H4 ) 10.60
8 Propane(C3H8) 2.29
9 Propylene(C3H6) 2.11
10 Iso-Butane(i-C4H10) 0.96

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11 n-Butane(n-C4H10) 0.44
Trans-2-
0.08
12 Butene(C4H8)
13 Cis-2-Butene(C4H8 ) 0.04
14 1-Butene(C4H8) 0.04
15 Iso-Butylene(i-C4H8) 0.07
16 i-Pentane(i-C5H12) 0.30
17 n-Pentane(n-C5H12) 0.02
Carbon
2.96
18 monoxide(CO)
Total 100.00

CALCULATION OF FURNACE EFFICIENCY:

First we calculate the weight of the given gases in the fuel gas by using the mole percent
which is given above. Then from the calculated weight we calculate weight percent. By using
the calorific values i.e. Low Heat Value (LHV) and Height Heat Value (HHV) we calculate
energy required by each component by using the formula (Q =M.S).

Secondly we are calculating the amount of individual elements i.e. carbon, nitrogen, oxygen,
hydrogen in the fuel gas. Now we have to calculate the theoretical oxygen and amount of
carbon dioxide and water vapour evolved (i.e. flue gas), theoretical Nitrogen.

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Thirdly we have to calculate the composition of flue gas with combustion of air and also
calculate the weighted average specific heat of the flue gas. From the above found data we find
the energy supplied for burning the fuel, heat lost due to radiation (surface loss).

Lastly by subtracting the energy supplied for burning, heat lost due to radiation from 100 we get
the furnace efficiency. The following calculation are done in excel docment.

All calculations that are done in the excel mentioned below:

GASEOUS FUEL : Calorific Value Quantities

S.No. Components Mole % Molecular Weight Weight(Kg) Weight% LHV HHV C H2 O2 N2 Volume(NM3)
kcal/Kg kcal kcal/Kg kcal
1 Hydrogen(H2) 20.14 2 40.28 1.889358988 28670 1154827.6 34111 1373991.08 - 40.28 - - 451.136
2 Carbondioxide(CO2) 0.16 44 7.04 0.330215672 0 0 0 0 1.92 - 5.12 - 3.584
3 Oxygen(O2) 1.90 32 60.8 2.851862623 0 0 0 0- - 60.8 - 42.56
4 Nitrogen(N2) 24.61 28 689.08 32.32173513 0 0 0 0- - - 689.08 551.264
5 Methane(CH4) 24.36 16 389.76 18.28194039 11954 4659191.04 13289 5179520.64 292.32 97.44 - - 545.664
6 Ethane(C2H6) 8.92 30 267.6 12.55194799 11350 3037260 12417 3322789.2 214.08 53.52 - - 199.808
7 Ethylene(C2H4 ) 10.60 28 296.8 13.92159254 11272 3345529.6 12028 3569910.4 254.4 42.4 - - 237.44
8 Propane(C3H8) 2.29 42 96.18 4.511383998 11079 1065578.22 12050 1158969 82.44 18.32 - - 51.296
9 Propylene(C3H6) 2.11 40 84.4 3.958835615 10942 923504.8 11700 987480 75.96 12.66 - - 47.264
10 Iso-Butane(i-C4H10) 0.96 58 55.68 2.61170577 10904 607134.72 11828 658583.04 46.08 9.6 - - 21.504
11 n-Butane(n-C4H10) 0.44 58 25.52 1.197031811 10932 278984.64 11856 302565.12 21.12 8.8 - - 9.856
12 Trans-2-Butene(C4H8) 0.08 56 4.48 0.210137246 10778 48285.44 27336 122465.28 3.84 0.64 - - 1.792
13 Cis-2-Butene(C4H8 ) 0.04 56 2.24 0.105068623 10831 24261.44 11589 25959.36 1.92 0.32 - - 0.896
14 1-Butene(C4H8) 0.04 56 2.24 0.105068623 10828 24254.72 27442 61470.08 1.92 0.32 - - 0.896
15 Iso-Butylene(i-C4H8) 0.07 56 3.92 0.18387009 10749 42136.08 27274 106914.08 3.36 0.56 - - 1.568
16 i-Pentane(i-C5H12) 0.30 72 21.6 1.013161721 10813 233560.8 11700 252720 18 3.6 - - 6.72
17 n-Pentane(n-C5H12) 0.02 72 1.44 0.067544115 10840 15609.6 11733 16895.52 1.2 0.24 - - 0.448
18 Carbonmonoxide(CO) 2.96 28 82.88 3.887539049 2416 200238.08 2416 200238.08 35.52 - 47.36 - 66.304
Total 100.00 2131.94 100 15660356.78 17340470.9 1054.08 288.7 113.28 689.08 2240

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CALCULATION FOR FLUE GAS QUANTITY : BASIS : 100 kgs of Fuel Gas

Component Weight Theoritical O2 (kgs) CO2 H20

C 49.44 131.85 181.29

H 13.54 108.33 121.87
O2 5.31 0.00
N2 32.32 0.00
Total 100.62 240.18

Attributes Value Unit

Theoritical Air Required 1044.26 kgs / 100 kgs of Fuel gas
Theoritical N2 in Flue gas 975.96 kgs / 100 kgs of Fuel gas
Theoritical Flue gas generated 1279.12 kgs / 100 kgs of Fuel gas
Excess Oxygen 2.60 %
Excess Air 15.03 %
Excess air supplied 156.94 kgs / 100 kgs of Fuel gas
Actual air supplied 1201.20 kgs / 100 kgs of Fuel gas
Excess Oxygen 36.10 kgs / 100 kgs of Fuel gas
Excess Nitorgen 120.84 kgs / 100 kgs of Fuel gas
Total Flue gas Quantity 1436.06 kgs / 100 kgs of Fuel gas

Component kgs Wt % Molecular wt. kg-moles

CO2 181.29 12.62 44.00 4.12

H2O 121.87 8.49 18.00 6.77

O2 36.10 2.51 32.00 1.13

N2 1096.80 76.38 28.00 39.17

1436.06 100.00 51.19

IMPORTANT RESULTS :
CALORIFIC VALUE ( LHV ) 7346 kcal/kg 13222 Btu/lb
CALORIFIC VALUE ( HHV ) 8134 kcal/kg 14641 Btu/lb
AVERAGE MOLECULAR WEIGHT 21.3 gm/gmmole -

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C:H Ratio of Fuel Gas 3.65 w/w -

H:C Ratio of Fuel Gas 0.27 w/w -
N:C Ratio of Fuel Gas 0.65 w/w -
ULTIMATE ANALYSIS OF FUEL GAS :
CARBON ( C ) 49.44 % Wt.
HYDROGEN ( H2 ) 13.54 % Wt.
OXYGEN ( O2 ) 5.31 % Wt.
NITROGEN ( N2 ) 32.32 % Wt.
FLUE GAS ( kg / kg OF FUEL GAS ) 12.79 -
STOICHIOMETRIC AIR (kg / kg OF FG) 10.44 -
MOLECULAR WEIGHT OF FLUE GAS 28.05 gm/gmmole -

FURNACE DATA
:

Attributes Values

Furnace Tag no. xyz

Fuel Gas Flow 2.00 MT/hr
1.46
Fuel Gas Pressure
kg/cm2g
Fuel GasTemp. 45 °C
Stack Temp. 138 °C
Fire Box Temp. 1000 °C
Ambient Temp. 35 °C
O2 in Flue Gas 2.60 % v/v

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COMPOSITION OF FLUE GAS WITH TOTAL COMBUSTION AIR :

Components Qnty. With FG Firing (kg) WT % Mol. Wt.( kg / kg-moles ) Kg-moles Volume / Mole (%)

CO2 906 12.62 44 20.60 33.88

H2O 609 8.49 18 33.85 55.68
O2 180 2.51 32 5.64 9.28
N2 5484 76.38 28 195.86 322.13
TOTAL : 7180 100.00

WEIGHTED AVERAGE SPECIFIC HEAT OF FLUE GAS

Cp of Flue Gas formed by Fuel Gas burning 0.2683
Flue gas generated from Fuel Gas 28721.3

FURNACE EFFICIENCY CALCULATION

Energy supplied by burning fuel 14691180 kcal
Heat loss due to dry flue gas 198462 kcal
Heat loss due to dry flue gas 1.4 %
Radiation loss, on Heat Realease (SURFACE LOSS) 881471 kcal
Radiation loss, on Heat Realease (SURFACE LOSS) 6 %
Furnace Efficiency Calculated (LHV) 92.6 %

CORRECTED FLUE GAS COMPOSITION

Component kgmoles mole fraction
CO2 20.60 3.65262
H2O 33.85 6.00245
O2 5.6401 1.00000
N2 195.86 34.72629
Total : 255.95

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