ATMOSPHERIC AND VACUUM UNIT

INTRODUCTION

In IOCL, Barauni Refinery, there are three Atmospheric and vacuum unit(AVU) units, AVU-1
and AVU-2 are for low sulphur crude oil and AVU-3 can process both low and high sulfur crude
oil. AVU is the mother unit of any refinery. Crude is first of all processed in this unit. It operates
at atmospheric pressure for fractional into Gas, LPG, Naptha, ATF, Kerosene, Diesel, and
Reduced crude oil (RCO). RCO is fractionated in vacuum distillation unit (VDU) to get VGO
and raw lube cuts.

The raw streams from AVU are treated in Hydro treatment, Reforming, Isomerization and Fluid
Catalytic Cracking plants to obtain components of finished saleable products. VGO is treated in
RFCCU to get LPG, Propylene, Petrochemical feedstock and components for moto spirit and
diesel. Raw lube cuts are treated for removal of aromatics and wax and are hydro treated to get
lube oil base stock. The short residue obtained from AVU fractionator bottom is partly treated in
coker unit to get lighter value added products along with raw petroleum coke. Vacuun residue
can also be treated to extraction unit, dewaxing unit and hydrofinishing unit to obtain bright
stock which is used for Lube oils and grease manufacture. Ashphalt and vacuum residue can also
be utilized for production of bitumen or as fuel for furnaces and boilers. From RFCCU, olefins,
propylene, various aromatics and naptha are obtained which are used as raw materials for
polypropylene, various aromatics and naptha are obtained which are used as raw materials for
polypropylene and aromatic petrochemical plant. The Raw Petroleum Coke (RPC) is used for the
generation of power and calcined petroleum coke. Sulphur preseent in crude and various sreams
is covered to H2S during processing. In sulphur plant, it is converted to elemental sulphur which
is sold as by-product. This also helps in environmental protection. Hydrogen plant is installed to
produce hydrogen for meeting the requirement of various hydro treatment processes.
Distillation

Distillation is a method of seperating the components of a solution which depends upon

distribution of the substance between gas and liquid phases. Its basic principle is that when a
solution of two or more components is boiled, then lighter the component more easily it
vaporizes. This results in the vapor above the liquid being relatively rich in the lighter, more
volatile material. The liquid is left with proportionally more of the less volatile or heavier liquid.

Fractional Distillation

Fractional Distillation is the seperation of a mixture into its component parts, or fractions, such
as in seperating chemical components by their boiling point by heating them to a temperature at
which one or more fractions of the compound will vapourize. It is a special type of distillation.
Generally the component part boils at less than 250C from each other under a pressure of 1atm. If
the difference in boiling points is greater than 250C, a simple distillation is used.

In most cases, the distillation is operated at a continuous steady state. New feed is always being
added to the distillation column and products are always being removed. Unless the process is
disturbed due to changes in feed, heat, ambient temperature, or condensing, the amount of feed
being added and the amount of product being removed are normally equal. This is known as
continuous, steady state fractional distillation.

Industrial distillation is typically performed in large, vertical cylindrical columns known as

"distillation or fractionation towers" or "distillation columns" with diameter ranging from about
65cm to 6m and heights ranging from about 6m to 60 m or more. The distillation tower have
liquid outlets at intervals up the column which allow for the withdrawal of different fractions or
products having different boiling points or boiling ranges. By increasing the temperature of the
product inside the column, the different hydrocarbons are separated. The "lightest" products
(those with the lowest boiling point) exit from the top of the column and the "heaviest" products
(those with the highest boiling point) exit from the bottom of the column.
PROCESS DESCRIPTION

CRUDE OIL PRETREATMENT (DESALTING)

The crude oil is contaminated with various impurities - mainly salts of Ca, Mg, Na, Cl, SO 4, etc.
These salts are, however, in small proportions is crude, can cause severe corrosion in crude units,
particularly in the overhead section. So it is important to remove the salts from crude prior to
distillation. The desalters are designed for 99% salt removal and reach less than 1 part per
thousand barrels in desalted crude.

Crude oil received from refinery tank farm (RTF), each tank having 40000 m3, is heated from
30oC to 140-150oC in cold preheat trains thus reducing viscosity and surface tension for easier
mixing and separation of water. This is done by recovering heat from outgoing products streams
from the unit. Then it is passed through a desalter after being mixed with demulsifier( chemical
surfactant) and water though a mixer valve at pressure of 10kg/cm2. Water dissolves in inorganic
salts are de-emulsifier facilitates coalescence of fine water droplets in the desalter wherefrom
water is seperated from mixture. In the desalter, crude passes through high electric field under
very high voltage of 12kV. The salt dissolved in water settles at the bottom as brine and desalted
crude with less than one part per thousand barrels comes out from the top of the vessel. Often
ammonia is added to reduce corrosion and caustic or acid may be addes to adjust the pH of the
water wash. Desalters remove salts, sludges and mud from crude to avoid corrosion and fouling
in exchanger's columns and downstream equipment.
PRE-TOPPING COLUMN (K1)

As the name suggests this column is used before main fractionating column. This is done for
increasing the productivity of the process and making it more efficient. The desalted crude at a
temperature of 23oC enters the column and flashes into liquid and vapour.

Inside the tower the liquids and vapours are always at their bubble points or dew points
respectively. So highest temperature is at the bottom and there by strips out the light portion of
the feed, it is also an alternative source of heat. The overhead vapor from the main fractionator is
condensed and cooled in the trim cooler; the condensed gasoline at a temperature of 45 oC is
collected in the 2-way reflux vessel.

A part of the gasoline is sent as reflux to the column under flow control for maintaining the
temperature of the top column. The other part is pumped to naptha caustic wash. Sour water
collected in the boot is drained under level control of the vessel. Gases from the top of the reflux
vessel are sent to the flare under control of the hydrocarbon level.

The next side stream from the column is of kerosene. A part of this kerosene goes to the kero
stripper where the light ends are stripped by system. The vapour goes back to the main
fractionating column. The stripped bottom is sent to rundown via heat exchangers. The balance
kerosene is pumped as circulating reflux-exchanging heat with incoming crude in various heat
exchangers for maintaining the temperature of the column.

The next stream is of LPG and LGO cr. LGO is product is condensed while the LGO cr is sent
back to the column as circulating reflux.
MAIN FRACTIONATOR (K2)

Inside the tower, the liquids and vapors are always at their bubble points or dew points
respectively. So highest temperature is at the bottom and lower temperature is at the top of
the column.

Stripping stream is given in the bottom of the column which decreases the partial pressure
thus the boiling point of the hydrocarbon inside the column and thereby strips out the lighter
portion of the feed . It is also an alternative source of the heat.

The overload vapors from the main fractionating column is condensed and cooled in the air
condenser to 650C and further cooled in the trim cooler. The condensed gasoline at a temperature
of 45oC is collected in the 3-way reflux vessel. A part of the gasoline is sent as reflux to the
column under flow control for maintaining the temperature of the column top.

The other part is pumped to naptha caustic wash. Sour water collected in the boot is drained
under level control of the vessel. Gas from the top of the reflux vessel is sent to the flare under
control of the hydrocarbon level.

The next stream from the column is of kerosene, a part of this kerosene goes to the kero stripper
where the lighter ends are stripped by steam. The vapour from the stripper goes back to main
fractionating column. The stripped bottom is sent back to rundown via heat exchangers. The
balance kerosene is pumped as circulating reflux-exchanging heat with incoming crude in
various heat exchangers for maintaining the temperature of the column.

The side stream is of LGO & LGO cr. The LGO product is condensed while the LGO cr is sent
back to the column as circulating reflux. HGO & HGO cr come from the next side stream. HGO
product is condensed while HGO cr is sent back to the column as circulating reflux.

The bottom product of the column is RCO which is pumped into the furnance for heating it to a
temperature of 46oC and then flashed in the vacuum column.
NAPHTHA STABILIZER COLUMN (K4)

From k1, the top product which is mixture of naphtha and LPG enters into naphtha stabilizer
column to separate naphtha from tits lighter fractions. Lighter ends (propane and butane) are
removed to reduce the vapor pressure of naphtha so that it can be used in automobile engine
without the fear of any vapor locking, while LPG which is removed is cooled, condensed and
taken into reflux drum wherefrom a part of it again fed back and remaining part is sent to LRU.

VACUUM COLUMN

The RCO which can't be further process in AVU is fed to the vacuum column. The overhead
vapours from the column are sent to the pre-condenser where Stream and other condensable are
sucked by ejectors and sent to the series of ejectors condensed from where the condensed liquid
goes to the hot well. The non-condensable inert gases are bubbles through the hot well for
purpose of maintaining liquids.

First side stream from the column is LVGO & LVGO cr acts as circulating reflux for maintain
the temperature of the column. Product VGO joins as HSD streams, the 2nd side stream from the
column is HVGO & HVGO cr part of the stream is sent as internal reflux to the column. The
HVGO and HVGO cr are sent through heat exchangers for heating the crude. From the outlet of
heat exchanger HVGO is returned to the column.

The 3rd side stream is SLOP and over flash. A part of which is sent to stripping section as over
flash while balance is sent to suction or SR pumps.

The bottom product of the column is short residue, which is pumped to rundown via heat
exchangers. SR acts as a feed to various units like Coker and RFCCU.

RCO from the main fractionating column is feed to the vacuum column because further heating
in main fractionators can cause cracking in the column. Vacuum column operated below
atmospheric pressure. Lowering the pressure decreases the boiling point of the various
components in the crude and thus it can be further separated in the vacuum column. This
increases the overall yields.
Top of the vacuum column is provided with a demister to minimize the entrainment of liquids
droplets in the vapor going to the overhead condenser. The overhead condenser is taken to the
pre-condensers where the steam and condensable are condensed. The sour waater is pumped
back to the desalter water tank.
CATALYTIC REFORMING UNIT (CRU)

The purpose of CRU is to enhance the octane number by changing the octane number by
changing the hydrocarbon structure in the presence of catalyst and hydrogen. It is not
advantageous to operate reformer with lighter hydrocarbons. So splitter was required to get
suitable catalyst, but impurities act as catalyst-poison, so we need hydro-treater to remove
impurities and water.

General process description

CRU improves the quality of MS (petrol) by increasing its octane number or antiknock property.
The raw material is gasoline, received from AVUs column to tank in CRU. From tanks through
pumps it is fed into naphtha splitter column, where it is divided into 2 parts. Top portion i.e. light
naphtha is routed to HGU as feed to the unit after caustic wash. The bottom product i.e. heavy
naphtha is sent to the hydro-treater unit where its organic impurities like sulfur, N2, O2 are
removed and stripped off from top. The bottom product of the stripper i.e. DSN (de sulfrized
naphtha) is fed to CRU. In CRU, this DSN is aromatized or dehydrogenated by catalyst in
reactors along with hydrogen. This hydrogen is recycled with compressor; the excess h product
is compressed by h rich gas compressor.

The hydrocarbon from reactor goes to L.P. separator, the bottom of the separator is naphtha and
it is pumped H.p. separator through pump and the top of the L.P. separator goes to compressor.
The bottom of the H.P. separator is sent to the LPG separator. After removing the LPG, naphtha
is pumped to stabilizer column for residual LPG removal. The LPG from the top of the column
are removed and the bottom stabilized product is called reformate and sent as M.S. constituent.

The commonly used catalytic reforming catalysts are Pt and Rh which are very susceptible to S
and N compounds, so they are removed in pretreatment process.

The four major catalytic reforming reactions are:

1. The dehydrogenation of naphthenes to convert them into aromatics as exemplified in the
conversion methylcyclohexane (a naphthenes) to toluene (an aromatic), as shown below:

2. The isomerization of normal paraffins to isoparaffins as exemplified in conversion of normal

octance to 2,5-Dimethylhexane (an isoparaffin), as shown below:

3. The dehydrogenation and aromatization of paraffins to aromatics (commonly called

dehydrocyclization) as exemplified in the conversion of normal heptane to toluene, as shown:

4. The hydrocracking of paraffins into smaller molecules as exemplified by the cracking of

normal heptane into isopentane and ethane, as shown below:
 Contents
INTRODUCTION TO THE COMPANY

 OIL REFINERY

 OPREATION

 MAJOR PRODUCTS

FIRE AND SAFETY

 SOME COMMON CAUSES OF FIRE

 PREPARATION

THERMAL POWER STATION

 FUNCTIONING

 ORGANIZATIONAL STRUCTURE OF POWER PLANT

 OVERVIEW OF CAPTIVE POWER PLANT

 BOILER OPERATION

 DETAILED PROCESS OF POWER GENERATION IN A THERMAL POWER PLANT

 ROLE AND IMPORTANCE OF POWER PLANT

 GAS TURBINE

 STEAM TURBINE GENERATOR

 WATER TREATMENT PLANT AND STORAGE

AVU AND CRU

 Introduction

 Distillation

 Fractional distillation

 Process description

COKER
BOILER OPERATION
The boiler is a rectangular furnace about 50 feet (15m) on a side and 130 feet (40m) tall. Its walls
are made of a web of high pressure steel tubes about 2.3 inches (58mm) in diameter.

There are 6 boilers in the IOCL Barauni Refinery

1-4 are Russian boilers – capacity 75 TPH

5TH boiler is IJT manufactured boiler – capacity 75 TPH

6TH boiler is BHEL manufactured boiler –capacity 150 TPH

Furnace oil (FO) the at last product of the refining is used as a fuel to ignite the furnace. It is
blown into the furnace through burners located at the four corners, or along one wall, or two
opposite walls, and it is ignited to rapidly burn, forming a large fireball at the centre. The thermal
radiation of the fireball heats the water that circulates through the boiler tubes near the boiler
perimeter. The water circulation rate in the boiler is three to four times the throughput. As the
water in the boiler circulates it absorbs heat and changes into steam. The working pressure is

40kg/cm2. The temperature of the steam is 4400c. The boiler has cast steel water inlets at the
boiler and furnace at the centre. There is a steam separator to remove moisture from the steam.
GAS TURBINE
A gas turbine, also called a combustion turbine, is a type of internal combustion engine. It has an

upstream rotating compressor coupled to a downstream turbine, and a combustion chamber in-

between.

The basic operation of the gas turbine is similar to that of the steam power plant except that air is

used instead of water. Fresh atmospheric air flows through a compressor that brings it to higher

pressure. Energy is then added by spraying fuel into the air and igniting it so the combustion

generates a high- temperature flow. This high- temperature high- pressure gas enters a turbine,

where it expands down to the exhaust pressure, producing a shaft work output in the process. The

turbine shaft work is used to drive the compressor and other devices such as an electric generator

that may be coupled to the shaft. The energy that is not used for shaft work comes out in the

exhaust gases, so these have either a high temperature or a high velocity. The purpose of the gas

turbine determines the design so that the most desirable energy form is maximized. Gas turbines

are used to power aircraft, trains, ships, electrical generators, or even tanks.

Number of GTs- 2

Supplier- BHEL

Rating- 40Kg/cm2, 4400c.

Fuel Used- Naphtha.

Capacity of each- 48.5 TPH

COOLING TOWER
A Cooling Tower is a heat rejection unit which rejects waste heat to the atmosphere through the
cooling of a water stream to a lower temperature. Cooling towers may either use the evaporation
of water to remove process heat and cool the working fluid to near the wet-bulb air temperature
or, in the case of closed circuit dry cooling towers, rely solely on air to cool the working fluid to
near the dry- bulb air temperature.

 Fan – 3

 Speed in RPM – 100

 Motor -75MW, 0.4 KV, 1480 RP

COOLING TOWER FAN AND MOTOR

MOTOR MAKER: CROMPTON GEARERS

 V=0.4KV

 FULL ROAD CURRENT FOR FAN 1&2

 FAN RPM =10