REPORT ON VOCATIONAL TRAINING

AT

INDIANOIL CORPORATION LIMITED

HALDIA REFINERY

PERIOD OF TRAINING
(21st June – 17th July 2010)

DEPARTMENT OF CHEMICAL ENGINEERING

3 RD YEAR

SAMARSHI CHAKRABORTY
SANTANU ADHIKARY
AKASH PODDAR
KUNTAL MAITI

HALDIA INSTITUTE OF
TECHNOLOGY

1
DEPARTMENT CONCERNED :

 Training Department …………………………

 FuelOil Block (FOB) ……………………………

 Lube Oil Block (LOB) ……………………………

 DHDS …………………………...

 Oil Movement & Storage

2
 (OM&S)
…………………………..

PREFACE

Industrial training plays a vital role in the progress of

future engineers. Not only does it provide insights about
the industry concerned, it also bridges the gap between
theory and practical knowledge. We were fortunate that
we were provided with an opportunity of undergoing
Industrial training at INDIAN OIL CORPORATION
Ltd., Haldia, one of the leading refineries in India.

The experience gained during this short period was

fascinating to say the least. It was a tremendous feeling
to observe the operation of different equipments and
processes. It was overwhelming for us to notice how
such a big refinery is being monitored and operated with
proper co-ordination to obtain desired results.

During our training we realized that in order to be a

successful process engineer one needs to possess a
sound theoretical base along with the acumen for
effective practical application of the theory.
Thus, we hope that this industrial training serves as a
stepping-stone for us and helps to be successful in
future.

3
 Acknowledgement

We would like to express our deep sense of gratitude to Mr.

G.G.Gupta (Training Manager) for granting us permission to
undergo training at IOC, Haldia refinery over a period of 4 weeks
and for providing us with necessary inputs as and when needed.

We would also like to appreciate and acknowledge the efforts put

in by the Senior Production Managers. In spite of their busy
schedule, they were always eager to help us out and share their
vast experiences with us. We would also like to heartily thank the
shift engineers and operators who in spite of their arduous task
took time out to explain each and every detail of the processes and
also provided us with invaluable technical advices about every
aspect of the plant. We are really thankful to the staff for
cooperating with us immensely. We are thankful to the following
departments and their staffs for their insights on the industry.

Training Department:
• Mr. D.Sinha.
• Mr. B.K.Mondal.
• Mr. S.Bag.

Fuel Oil Block:

• Mr.S.K.Roy , PNM

4
Lube Oil Block :
• Mr.S.Samanta, SPNM
• Mr. Lalan Kumar Paul, DMPN
• Mr. R. Alam.

DHDS / RFCCU / SRU:

• Mr.S.Baitha, PNM
• Mr. Soumen Mondal., DMPN
• Mr. S. Partha.

Oil Movement & Storage:

• Mr. S K.Das, CPNM
• Mr. B.K.Panda, SPNM

Samarshi
Chakraborty

Santanu Adhikary

Akash Poddar

Kuntal Maiti

5
 INTRODUCTION

Petroleum is a naturally occurring liquid found in rock formations. It

consists of a complex mixture of hydrocarbons of various molecular
weights, plus other organic compounds. It is generally accepted that oil, like
other fossil fuels, formed from the fossilized remains of dead plants and
animals by exposure to heat and pressure in the Earth's crust over hundreds
of millions of years. Over time, the decayed residue was covered by layers
of mud and silt, sinking further down into the Earth’s crust and preserved
there between hot and pressured layers, gradually transforming into oil
reservoirs.

The most prolific and dynamic industries of this century are petroleum
and petrochemical. In recent decades, the energy industry has experienced
significant changes in oil market dynamics, resource availability and
technological advancement. However our dependence on fossil fuels as our
primary energy source has remained unchanged. It has been estimated that
global energy consumption will grow about 50% by the end of the first
quarter of the 21st century and about 90% of the energy is projected to be
supplied by fossil fuels such as oil, natural gas and coal. This significantly
reveals the magnitude, economic edifice and necessity of this industry. In
this supply and demand scenario, the need is for the development of
upgrading processes in order to fulfill market demand as well as to satisfy
environmental regulations. From the most primitive methods of extraction
and refining of petroleum, great transformation has occurred throughout
these years to materialize the modern refinery. INDIAN OIL
CORPORATION LTD. (IOCL) has been the pioneer of petroleum
refining in India over the last few decades.

IOCL: An Overview

6
 Indian Oil Corporation Ltd. (IOCL) is a major diversified,
transnational, integrated energy company, with national leadership and a
strong environment conscience, playing a national role in oil security &
public distribution. Indian Oil Corporation Ltd. (IndianOil) is India's largest
commercial enterprise. Beginning in 1959 as Indian Oil Company Ltd.,
Indian Oil Corporation Ltd. was formed in 1964 with the merger of Indian
Refineries Ltd. (established 1958). IndianOil and its subsidiaries account for
49% petroleum products market share, 40.4% refining capacity and 69%
downstream sector pipelines in India.

There are ten refineries under Indian Oil Corporation Limited

(IOCL) located at

• Guwahati (Assam)
• Barauni (Bihar)
• Baroda (Gujarat)
• Haldia (W.B.)
• Mathura (U.P)
• Panipat (Hr.)
• Narimanam
• Bongaigaon (Assam)
• Digboi (Assam)
• Chennai

The combined rate capacity of these ten refineries is

49.30MMPTA. IOC accounts for 42% of India’s total refining
capacity. The Corporation's cross-country network of crude oil and product
pipelines, spanning about 9,300 km and the largest in the country, meets the
vital energy needs of the consumers in an efficient, economical and
environment-friendlymanner.

The 5.8 MMTPA refinery at Haldia is the 4th in the chain of

refineries under IOCL.

7
 Haldia Refinery, the fourth in the chain of seven operating refineries
of Indian Oil, was commissioned in January 1975. It is situated 136 km
downstream of Kolkata in the district of East Midnapur, West Bengal, near
the confluence of river Hoogly and river Haldi. The refinery had an original
crude oil processing capacity of 2.5 MMTPA. Petroleum products from this
Refinery are supplied mainly to eastern India through two Product Pipelines
as well as through Barges, Tank Wagons and Tank Trucks. Products like
MS, HSD and Bitumen are exported from this refinery.

The strategic significance of this Refinery lies in its being the only coastal
refinery of the Corporation and the lone lube flagship, apart from being the
sole producer of Jute Batching Oil and Russian Turbine Fuel. Capacity of
the Refinery was increased to 2.75 MMTPA through de-bottlenecking in
1989-90. Refining capacity was further increased to 3.75 MMTPA in 1997
with the installation/commissioning of second Crude Distillation Unit of 1.0
MMTPA capacity. Diesel Hydro Desulphurisation (DHDS) Unit was
commissioned in 1999, for production of low Sulphur content (0.25% wt)
High Speed Diesel (HSD). With augmentation of this unit, refinery is
producing BS-II and Euro-III equivalent HSD (part quantity) at present.

Resid Fluidised Catalytic Cracking Unit (RFCCU) was commissioned in

2001 in order to increase the distillate yield of the refinery as well as to meet
the growing demand of LPG, MS and HSD. Refinery also produces eco
friendly Bitumen emulsion and Microcrystalline Wax. In addition, a
Catalytic Dewaxing Unit (CIDWU) was installed and commissioned in
2003, for production of high quality Lube Oil Base Stocks (LOBS), meeting
the API Gr-II standard of LOBS. This is the only refinery in the country to
produce such high quality LOBS.

In order to meet the Euro-III fuel quality standards, the MS Quality

Improvement Project has been incorporated for production of Euro-III
equivalent MS. Currently the unit is under stabilisation. At present, the
Refinery is operating at a capacity of 5.5 MMTPA. Refinery expansion to
7.5 MMTPA as well as a Hydrocracker project has been approved for Haldia
Refinery, commissioning of which shall enable this Refinery to supply entire
Euro –III HSD to the eastern region of India.

Fuel oil products include:

8
1. LPG.

2. Motor spirit (MS).

3. Mineral turpentine oil (MTO).
4. Superior kerosene oil (SKO).
5. Aviation turbine fuel (ATF).
6. Russian turbine fuel (RTF).
7. High speed diesel (HSD).
8. Jute batching oil (JBO C/P).
9. Naptha.
10. Furnace oil.

Lube oil base stocks are:

1. Inter neutral HVI grade.

2. Heavy neutral HVI grade.

3. Bright neutral HVI grade.

Beside the above, slack wax, carbon black feed stock (CBFS) , Bitumen,
sulphur are the other product of this refinery.

9
 Block Flow Dia
Fuel Gas
LPG

SR Naph C5 – 90°C

CRU
90 – 140°C

C C Kero Cut
D D KHDS
U U St.Run G.O
Crude
1 2 JBO

FIRE AND SAFETY:

The main & utmost thing , which is to beGOknown to all is the safety durin
working in an industry. A person in an industry should well aware about the
safety rules to keep safe himself & others from any unwanted SOmisshap.
The main principle points which one should keep in mind are-
V V LO / IO / HO
RCO
D D
U U
DAO
1. One should ware safety helmet to avoid injury.
1 2
PDA
10 Asp.
SR
 2. The second important thing is the safety shoes.

3. The third important thin is that one should ware

safety jacket during work.

4. When a person is poling heavy material he should

wear PVC gloves.

These are the major things which one should maintain during work. But
there are many small things which should be maintained properly.

a. A person should wear safety goggles during welding.

b. When a person is working at a high construction

he should wear safety belts.

11
c. A person should use a ladder having rubber
covered legs ,neither he can slip.

d. When a person is working in a chemically

hazard place he should use gas mask.

e. One should keep safe distance from furnace

& should operate it very carefully.

f. Workers should keep in mind that not to work near inflammable

gases.

g. The cylinder should store in proper manner &in proper places.

h.One should always keep safe distance from pit.

h. The fire extinguisher should kept in proper places

& after work workers should keep it back in the proper place.

i. If any problem occur regarding safety workers should immediately

inform his higher officers.

12
 These are some safety associated rule which one should keep in mind.
But these rule do not work until a person has a sense of safety.
Another main important thing is workers should know how to fight with
fire. To know this we have to know first what is fire.
In industrial language fire is nothing but a combination of heat,
inflammable material, oxygen, free radicals.
This is called fire tetrahedron. If on of the side is removed then it can be
controlled.

Now the next important thing is the type of fire extinguisher.

Type of fire extinguisher-
TYPE USE FOR CHEMICAL
• A general fire water, AFFF(aqueous
. film forming
foam)

• B fire from oil sand, water AFFF, .

. DCP(dry chemical .
. powder )

• C fire from gases CO2

• D metallic fire DCP

• E electrical fire CO2

[Note: During fighti with fire with CO2 one should always about the
direction of air flow, Because one may feint if he is in wrong direction .]

OVERVIEW OF HALDIA REFINERY

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 FUEL OIL BLOCK
Fuel Oil Block is the unit that takes the imported crude oil from
storage and performs the initial separation of broad components in an
atmospheric distillation column. These broad products are further modified
to other products which are treated, stored and finally marketed. In this sense
it can be called the mother unit of IOC (Haldia). It was commissioned in
August 1974, originally designed for processing Light Iranian Aghajari
crude but presently crudes like Arab Mix (lube bearing) and Dubai crude
(non-lube bearing) are processed. The capacity has been increased from 2.5
MMPTA to 4.6 MMPTA.

Fuel oil block produces fuel oil from crude and this block consist of eight
subunits as given below:

• CRUDE DISTILLATION UNIT (Unit 11 & 16)

1. Prefractionator section
2. Topping Section: Atmospheric distillation unit (ADU)
3. Naphtha stabilization unit
4. Naphtha re distillation unit

• GAS PLANT (Unit 12)

1. De-ethaniser
2. Amine-washing of LPG
3. De-propaniser

• MEROX UNIT (Unit 13)

1. LPG extractive merox
2. ATF/ Gasoline sweetening merox

• NAPTHA TREATMENT (Unit 14)

1. Naphtha caustic wash

• AMINE ABSORPTION AND REGENERATION

(Unit 15)
1. Fuel gas amine absorption system
2. Amine (DEA) regeration
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• NAPTHA PRETREATMENT UNIT (Unit 21)

• CATALYTIC REFORMING UNIT (Unit 22)

• KHDS UNIT (Kero Hydro Desulphurisation Unit)

Crude Distillation Unit:

IBP-140OC

GASOLINE

DESALTER
PREFRACTIONATOR

DIESEL

PRETOPPED
JBO (C) /
CRUDE
JBO (P)

FURNACE

RCO

CRUDE DISTILLATION UNIT

Principle of operation: The crude oil from storage tanks

(generally 35,000 cubic meters) is first taken to a set of heat exchangers for
preheating to about 120 °C-130 °C and introduced to the desalter setup for
95% desalting. The crude is then heated to 260-265°C in second set of heat
exchanger. Then it’s further heated up to 350-360°C in furnace. The hot
15
crude is distilled in an atmospheric distillation column to draw the following
products from different stages:

Sl No Stream Approx. Boiling Range(°C )

1. Gasoline ( overhead ) IBP – 140
2. Heavy Naphtha 140 – 160
3. SKO / ATF 160-271 / 160-240
4. HSD 271-320 / 240-320
5. JBO(C)/JBO(P) 320-360 / 320-330
6. RCO 360+ / 385+/>400+

OVERHEAD (IBP-140 O C CUT) REFINING: In the CDU,

IBP-140OC cut is fractionated into two products in stabilization column:

 Overhead product: very low boiling hydrocarbons up to butane (C4)

which is routed to the gas plant
 Bottom product: C5 –140OC cut which is sent to the to Naphtha re-
distillation column .

SPLITTING OF IBP-C 4 CUT: In GAS PLANT overhead product

from stabilizer column is fed to the de-ethaniser. Overhead stream
containing ethane is sent to fuel gas system of refinery, while bottom
product is amine washed for H2S removal (crudes being processed now
contain low H2S in the LPG range), hence amine washing is not required.

After amine washing, this stream is sent to Unit-13 i.e. Merox treatment
plant where mercaptan is removed. If the crude contains small
amount of H2S column 12C02 is bypassed as in that case
amine washing is not essential.

In MEROX TREATMENT UNIT ( Unit-13 ), light petroleum gas ( LPG )

obtained from gas plant is caustic washed and sent to LPG extractor (13C01)
where counter-current flow is observed . It is then sent to LPG storage.

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 A part of merox treated product is fractionated in depropaniser column
(12C07) to produce propane according to the requirement of Propane
deasphalting unit of Lube Oil Block (LOB). There is provision for blending
bottom product (C4) with Motor Spirit (MS).

SPLITTING OF C 5 -140 O C CUT: C5-140 OC cut is fractionated

in Naphtha Redistillation Unit (11C05) into two streams.
i) C5 – 90OC stream is routed to unit-14 for caustic wash
and removal of H2S and finally sent to naphtha storage.
ii) 90OC-140OC cut from bottom of 11C05 is used as fed
stack for catalytic reforming unit (unit 21& 22). Excess amount is sent
to unit-14 inlet to mix with C5-90OC cut.

PRODUCTION OF KEROSENE/ATF/MTO/RTF:
These products are obtained from kerosene draw-off and sent to intermediate
storage tanks for subsequent treatment in KERO-HDS unit (unit-13), which
will be described in relevant section. In kero-redistillation column 11C06,
top product is routed to ATF or MTO tanks and the bottom product is sent to
SK or HSD pool. Dosing i.e. addition of external material is an important
part of this present section.

DOSING OF ADDITIVE IN ATF RUN: Dosing with particular

compounds from outside to build up properties like high
conductivity and antifreezing property processes aviation turbine
fuel. Generally, Hiracon and Stadis 450 is dosed at a particular rate.
Hiracon acts as an antioxidant and reduces the chance of
inflammation.

Stadis 450 (Toluene and Isopropanol mixture) increases the heat

conductivity of product causing safer transport.

Generally funnel at the top of 23B09 is to be opened and from it 300 kgs.
of Hiracon and 37.5 kgs. of Stadis 450 are to be inserted .

PRODUCTION OF HIGH SPEED DIESEL (HSD): It is

drawn off from the column 11C01 and sent to HSD storage. SR gas oil is the
main component of HSD. The other components are heavy naptha, excess
JBO , vacuum gas oil,spindle gas oil etc.

17
PRODUCTION OF JBO(C) / JBO( P ): Jute Batching Oil
abbreviated as JBO (clear and pale) is directly drawn from main distillation
column in blocked out operation and is sent to JBO storage.

REDUCED CRUDE UTILIZATION: Reduced crude is sent to

VDU i.e. vacuum distillation unit (unit-31) for further fractionation into lube
oil distillation cuts.

PROCESS DESCRIPTION:

A. CRUDE OIL PUMPING : From storage crude is pumped

to first set of heat exchanger by crude feed pumps 11P02A and 11P02B
before desalting . A pressure switch to start up the spare pump is provided in
case of low discharge pressure of the running up.

B. PREHEATING OF CRUDE BEFORE DESALTER

: The pumped crude is taken to first set of heat exchanger for preheating
where they get warmed by exchanging heat with following streams :
 Top circulating reflux in 11C01
 SR gas oil in 11E04A & 11E04B
 Reduced crude in 11E03A & 11E03B
 Kerosene in 11E02

C. DESALTING OF CRUDE: An oil-water emulsion is

prepared by adding water either at the inlet of 11E01 or at the upstream of
desalter main valve (11PIDC06) or at both places by using pumps.

After proper mixing, the crude experiences an alternating electrostatic field

in the desalter. As a consequence, brine is settled at the bottom
and crude oil floats above brine section. This brine water from
bottom of 11B02 is sent to sour-stripper whereas desalted
crude from 11B02 top are pumped by 11P02A, 11P02B,
11P02C which are booster pumps in nature.

18
 D. PRETREATMENT OF CRUDE AFTER
DESALTING : After desalting operation,crude is again preheated to
around 265OC in a second set of preheat exchangers. In this case, crude gets
warmed by the exchange of heat with the following:

 Kero CR reflux in 11E05A/B/C

 JBO in 11E06
 RCO in 11E07A/B/C
 Gas oil (diesel) in 11E08A/B
 Diesel CR reflux in 11E09A/B/C/D
 RCO in 11E10A/B/C/D/E

E.HEATING IN THE FURNACE: Crude oil after preheating is

heated in the furnace 11F01. This particular furnace has four passes in each
of which flow is controlled by individual pass control valves numbered
11FRCV10/11/12/13.

In the furnace, heating of oil takes place in convection zone and radiation
zone where partial vaporization also occurs. It is then sent to flush zone of
the column under temperature control.

F.FRACTIONATION: Here crude oil is fractionated into

different streams, description of which is given below:

1. Top circulating reflux : It is withdrawn from 39th tray at about 160OC

and pumped by the pumps 11P08A/B. This reflux is cooled to 90OC in
11E01 by exchanging heat with crude oil .

2. Overhead steam : Gasoline vapour and stream from the top of the
column are condensed in 11E22A/B/C . Temperature of 125OC is
maintained at the top by means of external reflux . Condensed gasoline
vapour and water goes to accumulator 11b01 where 1.8-2.8 kg/cm2
pressure is maintained .

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3. Kerosene circulating reflux : From tray no.28 ,Kero-CR is drawn off
by pumps 11P09A/B . Heat recovery is done by method of reflux in naphtha
redistillation reboiler . 11E12 under temperature control and in the
exchanger 11E05A/B/C with crude oil . Reflux is then returned to column
under flow control.

4. Kerosene drawn off : Kerosene drawn off from 27th tray is sent under
level control to the stripper 11C02A. Lighter ends are stripped off by steam.
The kerosene from stripper bottom is sent to storage under flow control after
exchanging heat with crude oil in 11E02 and by water in cooler 11E18.

5. Diesel Circulating reflux : From 19th tray, Diesel CR is withdrawn and

pumped by 11P10 or 11PO93 . Heat recovery from C.R. is performed by
heating stabilizer bottom in the stabiliser reboiler 11E11 under temperature
control and by heating crude oil in exchangers 11E09A/B/C/D.

6. Diesel drawn off : Diesel oil (gas oil) is drawn off from 19th tray in
which level is controlled by 11LC14 and is sent to the stripper 11CO2B.
Lighter ends are stripped off by steam which returns to column .

7. Heavy naphtha drawn off : Heavy naphtha is withdrawn from 35th tray .
This is sent to stripper 11CO2D under level control 11LIC01. Light ends are
stripped off by steam. H.C. vapour and steam return to the column 11C01
and H.N. (heavy naphtha) coming from stripper bottom is pumped by
11P25A/B and ultimately sent to HSD unit or storage.

8. JBO drawn off : From 12th tray JBO is drawn off and sent to stripper
11C02 from bottom of which JBO is pumped by 11P06A/B. heat is
recovered from exchanger 11E06 and 11E16. JBO is then sent to storage
after cooling in water cooler 11E20.
9. Reduced crude oil : Bottom of column 11C01 is stripped for removal of
lighter ends and Reduced Crude Oil (R.C.O.) is cooled by exchanging heat
with crude oil in exchanger 11E10A/B/C/D/E/F,11E07A/B/C/D and
11E03A/B & is sent directly as feed to VDU at the temperature of about
110OC.
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GAS PLANT OF FOB (UNIT-12)

PURPOSE: The function of gas plant is to remove the lighter ends such
as methane, ethane from LPG in de ethaniser and to scrub LPG with amine
solution to remove H2S before feeding of LPG to de propaniser.

PROCESS DESCRIPTION

There are three sections in this plant

1. De-ethaniser
2. Amine wash column
3. Depropaniser

De-ethaniser: Here feed is discharged of stabiliser overhead

pump, which after being heated by exchangers enters the 16th tray of de-
ethaniser column. (Total no. of trays in this column are 24).

Amine wash column: In this column H2S is removed by

washing with lean amine (DEA) solution. LPG from the column bottom
goes through feed heater.

De-propaniser: From LPG merox unit the product LPG

coming out is splitted out into three sections.
a. Major part to LPG storage.
b. A part to LPG vapouriser.
c. Third part to depropaniser for separation of propane and
butane.

Feed is heated by depropaniser bottom in heat exchanger and enters

the 14th tray of column. Overhead vapour is controlled by a pressure-
controller. The column bottom is reboiled by steam in a reboiler in which
butane is the main component. The bottom steam is cooled in water coolers
and sent to LPG storage.

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MEROX UNIT OF FOB ( UNIT-13)

PURPOSE: LPG contains mercaptans, which are detrimental to the LPG

burners. Therefore it is necessary to remove mercaptans from LPG. This is
done by MEROX process. It involves the catalytic oxidation of mercaptans
to harmless disulphides. Chemical reactions involved in this process are:

RSH (mercaptan) + NaOH = NaSR + H2O

2NaSR + H2O + 1/2 O2 = 2 NaOH + R-S-S-R

(Sodium mercaptide) (Disulphide)

SPECIFICATION OF THE FEED STOCK

Steam Sp.gravity Total Sulphur Mercaptan

( at 60OF ) ( wt. % maxm) Sulphur
(wt % maxm)
V.B. gasoline 0.740 1.0 0.50
S.R. gasoline 0.671 1.0 0.85

PROCESS DESCRIPTION

Light mercaptans are extracted by caustic containing merox catalyst

and heavier mercaptans from LPG and gasoline steams are also extracted by
same procedure. The extracted mercaptans in caustic phase are oxidised to
disulphides, which are separated with regeneration of caustic alkali. For
heavier mercaptans the resulting disulphide remain in the gasoline and the
process is referred as merox sweetening.

Gasoline merox undergoes a caustic pre wash for removal of H2S and
then is fed to a perforated tray column where gasoline is counter-currently
extracted from caustic solution containing a merox catalyst. Light
mercaptans are transferred to caustic solution containing Na-mercaptides
and residual mercaptans are converted to disulphide in a fixed bed reactor
22
containing impregnated charcoal activated with merox catalyst. The oxygen
required is supplied by air injection at the inlet of the reactor. Caustic
solution is separated from gasoline by settling in gasoline caustic settler.
Gasoline passes through sand filter and under gravity is routed to storage
after injection of oxidation inhibitor i.e. antioxidant and copper deactivator
to avoid gum formation.

Caustic Regeneration: Caustic from merox unit is heated in a

double pipe heat exchanger and enters the oxidiser vessel where mercaptans
get oxidised to disulphides and mixture goes to disulphide separators where
the disulphide oil is separated as two layers. Regenerated caustic is sent for
recirculation.

Naphtha Caustic Wash Unit ( U-14 ) :

C5 - 90˚C is treated with caustic to remove H2S before sending to

the storage. Naphtha is washed with caustic solution in wash drum and the
naphtha from the drum is water-washed and sent to storage while the caustic
part is recirculated.

Amine Absorption & Regeneration Unit ( U-15 )

This section is consist of two part i.e. amine absorption and

regeneration. Sour fuel gas after passing through a filter (to remove
hydrocarbon liquid which causes foaming in the column) from the refinery is
fed to amine absorption system (15C02) is to remove H2S. Lean amine is
counter currently passed through fuel gas to remove 99% of H2S. Sweet fuel
gas from the top of the column is passed to coalescer for entrained amine
settlement. Rich amine from 15C02 column, hydro finishing unit and fuel
gas amine absorption column exchange heat with lean amine and fed to a
regeneration column (15C01) where stripped with steam to remove H2S.
Remove H2S is routed to SRU.

Naphtha Pretreatment and Reforming Units:

23
 Choice of naphtha:

Naphtha consists of mainly naphthalene (N) and

aromatics (A). This N +2A are known as reforming index. As octane
number is a function of aromatics content. Feed with high reforming
index is high of naphthalene content is thus can be used for catalytic
reforming. Again heavy cuts having high reforming index yields
easier condition. But unstable compounds in the part can lead to high
coke formation which can deactivation catalyst.

On the other hand light cuts devoid of naphthalene and

aromatics, contains stable compounds which can’t be reformed even
in presence of catalyst.

This leads to the choice of feed towards the 90-140ºC cuts.

PURPOSE: Pretreatment of naphtha is a hydro treatment process in

which specific cut is treated to remove undesirable materials prior it goes to
Reforming Unit as feed.

Raw naphtha cut cannot be fed into the reformer directly. Chemicals
like
Sulphur, Nitrogen, Water, Halogens, Olefins and Metals act as poison to
reformer catalyst. The removal of these poisonous materials is done by a
hydro treatment process, which is called Pretreatment of Naphtha or
naphtha-HSD process.

THEORY OF HYDROTREATMENT

A. SULPHUR COMPOUNDS: Removal of sulphur compounds is

essential to avoid poisoning of catalyst. Beside this sulphur removal helps to
improve the other quantities of gasoline like lead susceptibility, color
stability, corrosion rates etc.

Different types of S-compounds e.g. mercaptans, sulfides, thiophenes etc.

are also present in crude.

24
 In operating condition and in presence of catalyst the S-compound
reacts with H2 and form H2S.

REACTIONS:
R-SH ( Thiol) + H2 = R-H + H2S
R-S-S-R ( Disulfides) + 3H2 = 2R-H + 2H2S
R-S-R' ( Sulfides) + 2H2 = R-H + R'H + H2S

The allowable concentration of sulphur in reformer feed is preferably

10 ppm.

B. NITROGEN COMPOUNDS: Though possibility of

presence of nitrogenous compounds in naphtha is very low but basic and
non-basic types of compounds are found. .
Basic type is pyridine and quinoline and non-basic type is carbozo,
indoles and pyrroles.

• Pyridine + 5H2 = C2H6 + C3H 8 + NH3

• Indole + 4H2 = C5H12 + NH3
The allowable limit of nitrogen in reformer feed is less than 1 ppm.

C. METAL COMPOUNDS: These may be present as contaminants

of Na,As, Pb, Ni,Cu etc. Allowable limit is As : 1 ppb
( Pb + Cu ) : 1ppb

D. WATER: As water is also a poison for reforming catalyst, its content

should be within specified limit in reforming feed.

E.OXYGEN COMPOUNDS: Sometimes phenolic compounds are

present in naphtha and are removed as water. Maximum allowable limit of
water is 20 ppm.

25
PROCESS DESCRIPTION:

90-140 cut naphtha is taken from storage by pumping and mixed with
hydrogen make-up gas from CRU recycle compressor discharge.

The mixture is then heated in reactor where in presence of Co-Mo

catalyst S, N etc are converted to H2S, NH3 and olefins get saturated and
deposited on metal catalyst. Catalyst is regenerated on furnace and reactor
effluent after partly condensation during cooling, enter the separator drum
.The gas from the top is recycled by reciprocating compressor. The liquid
from the bottom is taken to stripper. Part of stripper bottom is sent to CRU
whereas the sour gas leaving the overhead is sent to fuel gas system.

Naphtha Hydro Desulphurization Unit ( U-21 ) :

In this unit naphtha is passed through a magnetic filter to extract the iron
pieces. Naphtha is mixed with H2 and recycle gas and preheated in heat
exchangers (21E01 A/B/C) using hot reactor effluent passing through the
tube side. Again the feed is taken to an open draft furnace (22F01) for heated
up to the reactor temperature. After heating it flow across the reactor
containing Co-Mo catalyst for desulphurization reaction takes place. The
effluent is then cooled in heat exchangers and taken to a separator drum
consist of demister above which the H2S accumulates. Liquid is then
preheated and sent to a stripper 21C01 column. The bottom of the stripper is
reboiler in the furnace and overhead vapor is condensed. A part of it is
refluxed and a part is taken out as pretreated naphtha.

Catalytic Reforming Unit ( U-22):

Petroleum naphtha consists mainly of paraffinic, napthenic and

aromatic hydrocarbons. Their relative amounts depend on the crude origin.
Aromatic content of crude is around 20.0% of total hydrocarbons.
Naphthenic hydrocarbons consist of mainly cyclopentane, cyclohexane and
their relative amount is also dependent on crude origin.

Among hydrocarbons the sequence of increasing octane nos. is as follows:

26
 Paraffins < Iso-paraffins< Olefins< Napthenes< Aromatics

PURPOSE: Prevention of knocking under high compression ratios is

achieved by increase in the octane value of the fuel in CRU. Upgrading low
octane gasolines catalytically is known as catalytic reforming. The octane
rating improvement is accomplished chiefly by reorienting or reforming the
low octane components into high octane components. Much desired
reformate is influenced by the characteristics of feed stock and catalyst.
PROCESS DESCRIPTION

In CRU main categories of reactions are as follows :

• Aromatisation of napthenes and paraffins
• Isomerisation of napthenes and paraffins
• Hydrocracking of paraffins
• Hydrogenation of paraffins
• Olefinic hydrogenation
Other secondary reactions as demethanation, hydrosulphurisation etc.
Main types of reactions are described below.
• AROMATISATION: This reaction is very fast and highly
endothermic
( ∆ H = + 50 kcal/mole).In this reaction ,Octane No. increases and rate of
this type of this type of reaction increases with increasing number of C
atoms.

Example : n-Hexane Benzene

This type of reactions produces Hydrogen

• ISOMERISATION: In this type of reactions hydrocarbons isomerise

to produce higher octane no. hydrocarbons .

Example : Diethyl Cyclopentane Methyl Cyclohexane

27
• HYDROCRACKING: In this type of reactions, napthenic and
paraffinic hydrocarbons are broken and olefins are formed. When partial
pressure of hydrogen is high, nearly all olefins become saturated by reaction
with hydrogen.

Example : C10H 22 + H2 Methyl Pentane + C4H10

• DEHYDROCYCLISATION: In this set of reaction, cyclisation of

saturated open chain hydrocarbons occurs by removal of hydrogen.

Example : C7H6 Methyl Cyclohexane + H2

• Reactions :

1. Dehydrogenation:

2. Isomerization:

3. Paraffin hydrocyclization:

4. Hydro cracking:

The following reversible reactions take place in three reactors

according to written below:

1st reactor:

1. Dehydrogenation
2. Isomerization

2nd reactor:

1. Dehydrogenation
2. Isomerization
3. Hydro cracking
4. Dehydrocyclization

3rd reactor:

28
 1. Hydro cracking

2. Dehydrogenation

Process description: Pretreated naphtha is pumped to the heat

exchanger’s (22E01) shell side. Hot reactor effluent flows through the tube
side. Vaporized feed fed to the furnace 22F01 for further heating up to the
reaction temperature. Then it is fed to flow reactor’s (22R01) high purity
Al2O3 extrudates impregnated with .3% Pt and .3% Rh catalyst bed. Due to
endothermic nature of the reaction the product temperature decreases and it
is again fed to a furnace 22F02 and then to the catalytic reactor 22R02. The
product again reheated and fed the third reactor 22R03. The hot reactor
effluent is cooled down in a series of heat exchangers and the vapor – liquid
mixture is taken to a separator. The gas from the top is recycled to the unit
21 and to KDS unit and liquid is fed to stabilizer column.

Process operating variable : Octane number is a function of

pressure and temperature and aromatic content of products.

Temperature: An increase in reaction temperature leads to an

increase in operation severity. More sensitive hydro cracking reaction leads
to a high coke deposit decreases the catalyst activity.

Reactor inlet temperature: In practice the reaction

temperature are kept constant. Generally with a decreasing reaction
temperature coke deposit in catalyst bed is small and hence gives catalyst
gain. Sometimes due to high naphtha content the endothermic heat of
reaction is so high that it is impossible to make up for a furnace and a
decreasing temperature patterns follow.

Pressure: Although pressure during a operation can’t change, it can

influences to a large extent the quality of the product.

A decrease in pressure leads to a more complete aromatization, the

desired object of reforming and at the same time limits hydro cracking, a
parasitic reaction. Thus a lower pressure leads to a higher yield of desired

29
products and decrease in amount of light products (from methane to butane).
However as an adverse effect, a decrease in pressure leads to further
deactivation catalysts as with the decrease in H2 partial pressure coke
formation increases.

This deactivation may be compensated to a large extent by an

increase in recycle rate. Thus for optimum equipment design of a reforming
unit a precise choice of operating condition (pressure and recycle rate) has to
be made. This choice is guided by an economic balance between the yields
to obtain the life of the catalyst and power consumption of recycle
compressor.

Space velocity: Reduction of space velocity favors hydro cracking.

Thus increases octane number but reduces yield. Hence, temperature is kept
low when reducing flow rate.

Catalyst: Catalyst deactivation takes place due to coke formation,

metal poisoning, water poisoning etc.

Kero Hydro Desulphurization Unit ( U-23 ) :

FEED: The unit processes four raw kerosene distillate cuts produced from
Atmospheric Distillation Unit (ADU) of light Iranian Export Crude Oil.
1. TBP Fraction 140 – 271 OC
2. TBP Fraction 140 – 247 OC
3. TBP Fraction 140 – 240 OC
4. Mixture of TBP Fraction 140 – 271OC & TBP Fraction 170
– 271OC

FEED SPECIFICATIONS: Raw kerosene distillates are available

from storage at the following conditions:
Temperature: 40 OC
Pressure: 1 kg/cm2 abs.

PRODUCT : The unit can produce three different qualities of kerosene:

• Superior Kerosene ( SK )
• Mineral Terpentine Oil ( MTO )
• Aviation Turbine Fuel ( ATF )

30
PROCESS DESCRIPTION:

1. FEED AND GAS PREHEATING SECTION : Raw

kerosene feed from the storage is taken to the unit by pump
23P01A/B .The feed is subsequently blended with a mixture of
recycle and make up gases available from discharge of the
compressor 23K01A/B.

Both liquid feed and gas stream are heated in heat exchanger
23E02A/B/C/D in the shell side while the hot reactor-effluent passes through
the tube-side. Hot mixture of liquid and gas from 23E02A/B/C/D is taken to
the furnace .

2. FURNACE AND REACTOR SECTION: Preheated

kerosene and hydrogen are brought to the reaction temperature in the
furnace 23F01.

The heated feed then flows across a reactor 23R01 fitted with cobalt-
molybdenum catalyst where the desulphurization reaction takes place. In
reactor there is a distributor and 39 baskets in upper part of its section.
During the catalyst requalation service air is introduced at the furnace inlet
and at the same time an adequate quantity of medium pressure steam is also
introduced. During start-up nitrogen is introduced to the reaction inlet.

3. EFFLUENT COOLING SECTION: The effluent

from reactor is cooled and partially condensed in a series of heat exchangers.
Finally, this effluent is sent to the separator drum 23B01.

The reactor effluent is split into two phases in the separator drum 23B01.
I. The liquid phase is sent into stripper column 23C01
II. One part of vapour is sent to Hydrofinishing Unit of Lube Oil
block. Another part is recycled along with make up gas and compressed by
two parallel reciprocating compressor 23K01A/B.

31
 4. STRIPPING SECTION: The liquid from the separator
drum is reheated in exchanger 23E04A/B and fed into stripper column
23C01.

A part of the stripper bottom is reboiled in the heat exchanger 23e01

on the shell side. All the stripper bottom is pumped by 23P03, cooled and
sent to storage as finished product.

The stripper overhead vapours after leaving the top of column

23C01,are first cooled and partially condensed in the water cooler 23B02 .
The liquid distillate is returned as reflux by pump 23P02 to the top of
stripper column 23C01.

During Kero/MTO run total liquid distillate is refluxed. However

during ATF run, excess liquid distillate is sent to overhead drum 11B01 of
Atmospheric distillation Unit for recovery of light distillates .There is a
provision for rooting this light distillate to storage tank.

5. RECOMPRESSING SECTION: The gas from reflux

drum 23B02 goes via 23B02A to the first stage of the two parallel
reciprocating compressors.

The gas ,after cooling on water cooler is mixed with the steam from
LOB before sending to the knockout drum 23B04. the condensed
hydrocarbons from the drum are sent to stripper column. The vapour from
the knockout drum are compressed in the second set of compressors and
cooled in a water cooler . The vapour separated liquid hydrocarbons are sent
to fuel gas system or amine unit. The condensed hydrocarbons are drained
manually.

IMPORTANT DATA OF KERO HDS UNIT

1. CAPACITY: 5,77,500 MT/Yr. or 1690 MT/day

2. FEED PROPERTIES:
• Specific gravity at 15OC = 0.803
• TBP range = 140-271 OC

32
 • Total Sulphur ( wt. % ) = 0.90
3. CATALYST:
 Diameter : 1.5 mm
 Bulk density = 0.65 gm/cm2
 Pore volume = 0.50-0.55 cm2/gm.
 Chem. Composition :
1. CoO : 5.0%
2. MoO3 : 13.0 %
3. SiO2 : 1.0 %
4. Sulphate : 1.0 %
5. NaOH : 0.6 %
6. Al2O3 : Rest
4. OPERATING CODITIONS:
♦ Reactor inlet temperature : 340 OC
♦ Reactor outlet temperature : 375 OC
♦ Working pressure in reactor : 34.6
2
kg/cm
♦ Working temperature in reactor : 380 OC
♦ Stripper feed temperature : 139-140
O
C
♦ Stripper top temperature : 111-129OC
♦ Stripper bottom temperature : 200-215
O
C
♦ Stripper bottom pressure : 2.3 kg/cm2
FURNACE (23F01):

Type : Vertical

Diameter : 5.0 X 13.5 ft

Fuel used : Fuel oil from furnace

No. of tubes :

radiation section : 44 (V)
convection section : 24 (H)
 No. of burners : 4
STRIPPER ( 23C01)
9 valve trays -- Single pass type
17 valve trays -- Two pass type

33
 DIESEL – HYDRO DESULPHURISATION UNIT (UNIT
--25)

The diesel hydro desulphurization unit (DHDS unit), Unit 25, is based on the
Unionfining Process from UOP and is designed to process distillate oil.

Petroleum fractions contain various amount of naturally occurring

contaminants including sulphur, nitrogen and metals compounds. These
contaminants may contribute to increased levels of air pollution, equipment
corrosion and cause difficulties in the further processing the material.

The Unionfining Process is a proprietary, fixed-bed, catalytic process

developed by UOP for hydro treating a wide range of feedstocks. The
process uses a catalytic hydrogenation method to upgrade the quality of
petroleum distillate fractions by decomposing the contaminants with a
negligible effect on the boiling range of the bed. Unionfining is designed
primarily to remove sulphur and nitrogen. In addition, the process does the
job of saturating olefins and aromatic compounds while reducing Conradson
Carbon and removing other contaminants such as oxygenates and
organometallic compounds.

The desired degree of hydrotreating is obtained by processing the feed

stock over a fixed bed of catalyst in the presence of large amount of
hydrogen at temperature and pressures dependent on the nature of the feed
and the amount of the contaminant removal required.The Unionfining
catalysts are formulated by composing varying amounts of Nickel or Cobalt
with Molybdenum oxides on a alumina base.

Purpose: To reduce the sulfur content of the sour diesel and to produce
sweet diesel with sulfur content of less than 0.25/0.05 % by wt.

Sulfur removal: Feed stocks to the union fining .Unit contain simple
mercaptanes, sulfides and disulfides are easily converted to H2S. Feed stocks
containing hetero atomic, aromatic molecules are preceded by initial ring
opening and then sulfur removal followed by saturation of the resulting
olefins.

Mercaptan ⇒ C-C-C-C-SH + H2 = C-C-C-C-H +H2S

Sulphide ⇒ C-C-S-C-C + 2 H2 = 2 C-C-H + H2S

34
 Disulphide ⇒ C-C-S-S-C-C + 3H2 = 2 C-C-H + 2 H2S

Nitrogen removal: De-nitrogenation is generally more difficult

than desulphurization. The de-nitrogenation of pyridine proceeds by
aromatic ring saturation hydrogynolysis and finally de-nitrogenation.

Pyridine ⇒ Pyridine + 5 H2 = C-C-C-C-C (and iso-pentane) + NH3

Quinoline ⇒ Quinoline + 4 H2 = Ph-C-C-C + NH3

Pyrrole ⇒ Pyrrole + 4 H2 = C-C-C-C (and iso-butane) + NH3

Oxygen removal: Organically combined oxygen is removed by

hydrogenation of the carbon hydroxyl bond forming water and the
corresponding hydrocarbon.

Phenols ⇒ Phenol + H2 = Benzene + H2O

Olefin saturation: Olefin saturation reaction proceeds vary rapidly

and have high heat of reaction.

Linear olefins ⇒ C-C=C-C-C-C + H2 = C-C-C-C-C-C (and isomers)

Aromatic saturation: Aromatic saturation reaction is the most

difficult and exothermic.

Benzene + H2 = Cyclohexane

Metal Removal: Metals are retained on the catalyst surface by a

combination of adsorption and chemical reaction. Removal of metal
normally occurs from the top of the catalyst bed and the catalyst has a
certain maximum tolerance for retaining metals.

Metal contained in the crude oil are usually nickel and vanadium. Iron is
found concentrated at the top of the catalyst bed as iron sulfide, which is
corrosive.

Na, Ca and Mg are present due to the contact of the bed with salted
water or additives.

35
 Improper use of additives, to protect the fractionator overhead systems
from corrosion or to control foaming, accounts for the presence of P and Si.
Lead may also deposit on the hydro treating catalyst bed from reprocessing
leaded Gasoline through the crude unit. The total metal retention capacity of
the catalyst system can be increased by using a guard reactor or guard bed of
catalyst specially designed for de-metallisation.

Halide removal: Organic halides such as chlorides and bromides are

decomposed in the reactor. The inorganic ammonium halides sides, which
are produced when the reactor effluent is cooled, are dissolved by injecting
water into the reactor effluent or removed with a stripper off gas.

Chlorine removal ⇒ Ph-C-C-C-Cl + H2 = HCl + Ph-C-C-C-H

HCl + NH3 = NH4Cl

Process Description:

The DHDS unit consists of the following sections:

• Storage and transfer section.
• Reaction section.
• Compression section.
• Fractionation section.

Diesel from FOB enters this unit and passes through two-filter
separator of which one (25-FS-01 A&B) is gravity separator, which
separates water, and another (25-FS-02) is magnetic filter separator – which
separates magnetic metallic particles. The Diesel is then pumped and passed
through three heat exchangers in series for preheating. This preheated and
high-pressure diesel then enters into furnace and further heated there

Before entering the reactor, the diesel is mixed with hydrogen by

means of two compressors – one is used for recycling hydrogen obtained
from product stream, and another for make-up of hydrogen which comes
from the Hydrogen plant (Unit – 24). It then enters two reactors in series
(25-R-01 & 25-R-02). The outlet from the second reactor is used to preheat
the diesel oil in three exchangers described above. The product from reactor
i.e., diesel, hydrogen and H2S are separated in a separator vessel (25-V-02).
H2 and H2S is sent to an absorber column (25-C-01) in which H2S is amine-
36
washed using lean amine and the product rich amine is sent to ARU for lean
amine regeneration. Diesel and dissolved H2S are sent to stripping column
(25-C-02) with reflux in which diesel is found as bottom product. Top
product is H2S, H2O and light hydrocarbons (C1 & C2) are pumped to
absorber column (25-C-03) for amine wash. Amine washed H2S from
bottom of 25-C-03 is sent to ARU and sweet light hydrocarbon is sent to
fuel gas system.

Sulphur Recovery unit (Unit-28)

The sulphur recovery unit is designed to recover sulphur from the sour
vapors originating from the following sources:

 Amine Regeneration Unit. Unit-26

 Sour water stripper Unit-29

The process is a combination of conventional Claus process and the recently

developed process for the selective oxidation of hydrogen sulphide.

The SRU consists of the following sections:

1. A knock out drum for the feed gas stream and fuel gas stream.

2. A Claus Section, consisting of a thermal stage and three reactor

stages.

3. A super claus stage.

4. A thermal incinerator, burning the tail gas and vent gas of the
sulphur.

5. Degassing System.

6. A Sulphur pit with degasifying facilities and sulphur yards.

UNIT CAPACITY OF SRU:

Design Capacity: 60 metric tons per day

Turndown Ratio: 30% on the normal feed gas rate

37
On-Stream Factor: 8000 hr per day

FEED CHARACTERISTICS: The feed stock of SRU is a mixture

of “acid gas ex ARU” and “acid gas ex SWS”. The quality and quantity of
H2S feed to the unit will vary depending on the shut down of the various
preceding units. The unit should be capable of converting 99% Wt. of the
H2S content in the feed streams to sulfur in all cases.

PRODUCT CHARACTERISTICS:

The product sulphur meets the following specification after degasification,

State: Liquid Sulphur

Color: Bright Yellow

Purity: Minimum 99.9% on dry basis

H2S Content: 10 PPM wt. Maximum

CATALYST AND CHEMICALS:

1. CLAUS CATALYST:

These catalysts are installed in the Claus reactor.

1st & 2nd reactor, CRS-31, 85%wt. titanium oxide.

2nd & 3rd reactor, 98%wt. alumina with 2400 wt. PPM Na2O.

2. SULPHUR CLAUS CATALYST: It is a catalyst for

selective oxidation and consists of Al2O3 50% vol. SiO2 with iron (III)
oxide/ phosphate 50%vol. Catalyst is premixed by 50%/50% vol. by
manufacturers.

3. CERAMIC BALLS: A layer of ceramic balls (Denstone 57

type) is installed in the reactor as support bed.

38
 4.CHEMICALS FOR BFW: In SRU a phosphate injection
system is provided to increase the pH of boiler feed water to the WHB’s and
condenser.

To increase the pH, trisodium phosphate solution is injected and the

concentration of phosphate solution in the boiler and condenser is kept at 50-
100 PPM.

CHEMICAL REACTIONS INVOLVED IN SRU

CLAUS SECTION: The main reaction in this section takes place at

main combustion chamber.

H2S + 3/2 O2 = SO2 + H2O + Heat

The major part of the residual H2S combines with the SO2 to form sulphur,
according to the equilibrium reaction

2 H2S + SO2 = 3/2 S2 + 2 H2O - Heat

By this reaction known as Claus Reaction, Sulphur is formed in the main

burner and reaction chamber.

SUPER CLAUS SECTION: In this section partial oxidation of

H2S takes place according to the reaction

2 H2S + O2 == 2/8 S8 + 2 H2O + Heat

PROCESS DESCRIPTION:

CLAUS SECTION: By the reactions described above sulphur is

formed in vapor phase in the main burner and combustion chamber. The
primary function of waste heat boiler is to remove the heat generated in the
main burner. The secondary function of waste heat boiler is to utilize
removed heat to produce MHP stream. The process gas from the waste heat
boiler is passed into the first sulphur condenser, where the formed sulphur is
removed from the gas. The process gas leaving the sulphur condenser still
contains a considerable concentration of H2S and SO2. Therefore the essential
function of the following equipments is to convert these components to
sulphur. In the 1st, 2nd & 3rd reactor stages the H2S and SO2 again react to
39
form sulphur but this time at low temperature. In the super clause stage, the
remaining H2S is selectively oxidized to sulphur. For this reason it is
essential that the combustion in the main burner is such that in the down
stream of 3rd reactor stage the amount of H2S in the range of 0.5- 0.7%vol.
and the SO2 concentration is as low as possible. Before entering the first
reactor the process gas flow is heated by indirect steam to obtain the
optimum temperature for a high conversion of H2S and SO2 to elemental
sulphur and simultaneously a high conversion of COS and CS2 to H2S and
SO2. The effluent gas from the first reactor is routed to second sulphur
condenser. The process gas flow in next routed to second steam re-heater
and then to second reactor where equilibrium is established. The sulphur is
condensed in the 3rd sulphur condenser. From the 3rd sulphur condenser, the
process gas is routed to 3rd steam re-heater, and then passed to 3rd reactor
when equilibrium is established. The sulphur is condensed in the 4th sulphur
condenser.

SUPERCLAUS SECTION: The process gas from the 4th

sulphur condenser is routed to 4th steam re-heater then passed to reactor.
Before it enters the reactor, a controlled amount of air is added. Proper
mixing is obtained in static mixer. In the reactor sulphur S8 is formed
according to the reaction mentioned above. The formed sulphur is
condensed in 5th sulphur condenser. A sulphur condenser is installed
downstream of last sulphur condenser to separate entrained sulphur mist.
The sulphur condensed and separated in the condenser and coalescer is
drained via the sulphur logs and sulphur cooler into sulphur pits. The tail gas
leaving the coalescer still contains an amount of H2S which is dangerous if
released directly to atmosphere. Therefore, the gas is thermally incinerated,
converting residual H2S and sulphur to SO2 in presence of oxygen. After the
gas is cooled in incinerator, waste heat boiler and super heater it is routed to
the stock. In the incinerator and waste heat boiler, MHP steam is produced
and in the super heater MHP steam from the unit is superheated before
evaporation.

SULPHUR STRIPPING PROCESS: The process sulphur contains

H2S partially dissolved and partially present in the form of polysulphide.
Without treatment of sulphur, the H2S should be slowly released during
storage and transport. An explosive mixture may be created due to
exceeding the lower explosive limit of H2S in air, which may vary from 3.7
volume % H2S at 1300 C to 4.4 volume % H2S at ambient condition. The
shell sulphur degassing process has been developed to degasify liquid
40
 sulphur to 10 PPM wt. H2S / H2Sx which is the safe level to avoid exceeding
the lower explosive limit.

The function of this process is to enhance the decomposition of polysulphide

and to strip the H2S from the sulphur. Simultaneously, the greater part is
oxidized to sulphur. The air decreases the partial pressure of H2S and causes
agitation and circulation of sulphur. In this way, the H2S content is reduced
from approximately 350 to less than 10 ppm wt. the reduced H2S together
with the air is routed to the thermal incinerator, in which it is oxidized to
SO2.The degassed sulphur is pumped on level control to sulphur yard.

MOTOR SPIRIT QUALITY UPGRADATION UNIT

(MSQU)

NAPTHA HEART CUT

NAPTHA
PRODUCT

LPG

ISOMERIZATI
SR NAPTHA
NAPTHA LIGHT NAPTHA NHDT ON + DIH +
SPLITTER UNIT 85 LPG
RECOVERY
UNIT 85 UNIT 86
ISO
ME
RIZ HYDROGEN
HEAVY ATE
NAPTHA
REFORMAT
NHDT & E SPLITTER
CRU UNIT 85
UNIT 21 &
UNIT 22
MS PRODUCT
LIGHT FCC
GASOLINE

FCC GASOLINE
FCC GASOLINE SHU FCC HEART CUT
UNIT 87 GASOLINE
SPLITTER
UNIT 87

PRIME G+ SELECTIVE
HEAVY FCC DESULPHURIZATION
GASOLINE UNIT
UNIT 87

41
PYROLYSIS
GASOLINE

MSQ UNIT (UNIT-85,86,87)

This unit is known as the Motor Spirit Quality Upgradation unit. The unit is
commissioned with the aim to produce superior quality gasoline. Euro-II
type MS have a RON value of 88 and sulpher content of 50 ppm, and that of
the Euro-III is 91 and 150 respectively. The main product of MSQ unit is the
Euro-III type gasoline. Other constrains of Euro-III type MS is aromatic
content is 42%, benzene 1 %, olefin 21%, max by volume and the RVP is
0.6 kg/cm2. Hence the main objective of the unit is to convert the st chain
hydrocarbons, C5-C6 paraffin to branch chain, or olefins to improve the
octane number. As benzene is carcinogenic so benzene saturation is an
important factor in this unit. Reactions of type desulferisation, isomerisation,
and benzene saturation olefin saturations are done in these units. The light
FCC gasoline obtained after gasoline splitting in unit 87 is blended with
heavy reformate from unit 85, isomerate from unit 86, heart cut FCC
gasoline from unit 87, and heavy gasoline after hydrodesulphurization in
unit 87 are blended proportionately for octane improvement and
desulfurisation in the blending header to get MS of desired octane number.

RESIDE FLUID CATALYTIC CRACKING UNIT

Process Chemistry/Theory: Cracking process uses high

temperature to convert heavy hydrocarbons into more valuable lighter
products. This can be done either by thermal cracking or by catalytic
cracking. Catalytic cracking process has almost surpassed thermal cracking
because of inherent advantage of low temperature and pressure. Catalytic
cracking produces high octane gasoline, a more valuable cracked gas and
less of undesirable residual products.

Theory of catalytic cracking is based on the carbonium ion formation

and subsequent hydrogen transfer reaction. First step is the formation of a
carbonium ion from the feed stock. Carbonium ion is readily formed from
olefin. This reaction takes place on the active side of the catalyst. Once

42
carbonium ions are formed, they may either crack to form a small olefin plus
another carbonium ion reacts with another olefin to form a different
carbonium ion, isomerizes or breaks the chain by donating the proton back
to the catalyst. For dealkylation a tertiary amyl side chain comes off very
easily. Propyl, n-butyl, ethyl chains are progressively more difficult to
remove. The methyl group is generally not attached.

Next step is associated with the hydrogen transfer reaction which

converts olefins to paraffin. The source of hydrogen is another olefinic
hydrocarbon on the catalyst which will progressively become more
hydrogen deficient. This hydrogen deficient species will absorb very
strongly to the catalyst surface and deposit the coke on the catalyst during
reaction.

Brief process description: Fluidized bed catalytic cracking

unit consists of the following sections:

1. Feed preheat section.

2. Reactor/ Regenerator section.
3. Flue gas section.
4. Catalyst handling section.
5. Main fractionator section.
6. Product recovery section.
7. Amine treating section.

The main products coming out from FCCU are as follows:

1. Fuel gas.
2. LPG.
3. Gasoline.
4. TCO (Total cycle oil).
5. CLO (Clarified oil).

Feed preheat section: Cold feed from F.C.C.U. feed tank and
hot feed from process units are combined and received in storage drum. Cold
feed enters feed surge drum on level control and hot feed enters surge drum
on flow control.

A water boot on the drum allows manual draining of water accumulated

during start-up upset conditions. The feed drum pressure floats on the main

43
fractionator by means of a balance line which ties into the fractionator below
the LCO (light cycle oil) drawing chimney tray.

Fresh feed is pumped by fresh feed pump to the preheat circuit. The feed
preheat circuit comprises 11 heat exchangers in series. The fresh feed after
preheat attains a temperature around 1880 C (for feed 3) and 2550 C (for feed
2). Fresh feed is heated in these exchangers against lean oil, HCN, LCO,
LCO pump-around, HCO pump-around and slurry pump-around.

For feed 2, final feed is preheated in the fired heater before being sent to
the riser feed nozzles of the reactors.

For feed 3, slurry pump-around passes completely. Feed heater will be

operating at a minimum operating duty. If preheat temperature is still higher
than the required, other feed preheat exchangers are by-passed also.

Reactor /regenerator section: Preheated feed is finely

atomized and mixed with dispersion steam in four feed injectors mixing
chamber and injected to the riser. Above the feed injectors two HCO recycle
oil injectors are provided to maximize distillate production. Above the
recycle oil injectors, a recycle slurry backwash injector is provided. Also a
visbreaker naphtha injector is provided below the feed injector at riser
bottom. Dispersion steam (MP steam) is supplied through individual flow
control to each injector for proper atomization and vaporization of oil.

The fined atomized feed is contacted with hot regenerated catalyst and
vaporizes immediately. The vaporized oil mixes with the catalyst particle
and cracks into lighter more valuable products.

The heat required for the reaction is supplied by hot regenerated catalyst.
The residence time in the riser is approximately 2 sec. at design conditions.

Riser outlet temperature is regulated by controlling the flow of

regenerated catalyst by the regenerated catalyst slide valve (RCSV).

Catalyst separation from hydrocarbons/steam vapour is necessary to avoid

any undesirable continuation of the reaction which produces light gases at
the expense of valuable liquid products.

After existing the initial separator the vapour passes through two high
efficiency single-stage cyclones to complete the catalyst separation from
44
hydrocarbon products, thus minimizing the amount of catalyst lost to
product. The product containing a small amount of inert gas and steam flows
to quench zone of main fractionator. Small quantity of catalyst contained in
the product is carried to the fractionator slurry circuit.

Pressure controller at the wet gas compressor knock-out drum provides

the steady operating pressure of the reaction system.

Catalyst emitting the initial separator is prestripped with MP steam to

reduce coke yield and further stripped with steam. A series of baffles
enhances the contacting of steam and spent catalyst. The stripping steam
displaces the volatile hydrocarbon contained in the catalyst particles before
they enter the first stage regenerator.

The stripped spent catalyst flows down through the catalyst standpipe
and spent catalyst slide valve (SCSV) which controls the stripper level by
controlling flow of spent catalyst from the splitter.

Spent catalyst flows to the first stage regenerator through a distributor

which drops catalyst on the regenerator catalyst bed.

60%-70% of the coke is burnt in the first stage regenerator and rest in the 2nd
stage regenerator.

Combustion air for combustion process in regenerators is supplied by

combustion air blower driven by steam-turbine.

The hot regenerated catalyst flows to the 2nd stage regenerator through a
lateral connection to the withdrawal well (WDW) from which catalyst flows
down to the regenerated catalyst pipe (RCSP),

The RCSV and 450 C stand section to the reactor riser base where catalyst
begins the upward flow towards the fresh feed injectors.

1st stage regenerator internal primary and secondary cyclones and 2nd
stage regenerator internal primary and secondary cyclones separate the
entrained catalyst from the flue gas existing the 2nd stage regenerator. Flue
gas existing both regenerators flows to the flue gas section.

Flue gas section:

45
 The flue gas from the 1st stage regenerator passes through a double disc
slide valve (DDSV1) for controlling the differential pressure between the 1st
and 2nd regenerators. An orifice chamber is provided immediate downstream
of the 1st and 2nd regenerator slide valve to reduce the flue gas pressure. As
the flue gas passes through each plate the pressure is gradually reduced to
the desired outlet pressure. The pressure reduction is the function of the fuel
gas volumetric flow rate. To compensate for the varying flow rate through
the orifice chamber the slide valve provides the flexibility needed in
processing varying fresh feed rate.

The CO rich flue gas exists the orifice chamber and enters the incinerator
to convert CO to CO2 to comply with environmental emission requirement.

Catalyst handling

Hoppers are used for storage and transfer of fresh equilibrium and spent
catalyst. Hopper pressurization is required prior to loading catalyst into
FCC. Pressure is lowered when catalyst moves from regenerator to hopper
or for loading fresh catalyst. Blower air is used for transportation of catalyst
and aeration connections are also provided. Batch loaders and purge streams
are provided to prevent back flow.

Main fractionator column

The fractionator 18C10 consists of 30 valve trays and 8 rows of shed

decks. The reactor effluent, comprising of cracked hydrocarbon vapor, steam
and inert gas enters the column at the bottom of the quench section. In this
section, products are cooled and condensed. The slurry pump around and
decanted oil are withdrawn from the bottom and returned to the top of shed
decks. Entrained catalyst is removed from the decant oil in slurry filter
18S01. Fractionation liquid has a tendency for coking. Quench steam is
injected to prevent this.

Sponge absorber lean oil is withdrawn out of fractionator, cooled used as

lean oil in sponge absorber. Rich gas from bottom of absorber is returned to
fractionator. The total fractionator overhead vapors consist of HCN, LCN,
lighter hydrocarbons, steam and inert gases plus tower top reflux. These are
condensed in overhead condenser 18EA11 and separated from the gas in
overhead receiver 18B11.

46
Product Recovery System

Wet gas from overhead receiver is compressed to 16.9kg/cm2 by 2 stage

centrifuge compressor 18K10. The uncondensed vapors, medium pressure
distillate and sour water are separated in 18B13.

The uncondensed vapors are sent to primary absorber 18C14 for C3 and
C4 recovery. The absorber overhead products are mixed with lean oil and
get separated in the reflux drum 18B15. The unabsorbed vapors are routed to
sponge absorber 18C15 and semi rich naphtha is pumped to the top tray of
primary absorber. The rich oil from the bottom of the absorber is contacted
with wet gas compressed effluent from the compressor before flowing to
high pressure separator. The off gas flow to amine section for H2S and CO2
recovery. The stripper is designed to remove inerts, C2 and lighter
hydrocarbons from liquefied C3 hydrocarbon stream. The stripper overhead
is cooled and collected. The stripper bottom is sent to a debutanizer where
C3, C4 are separated. Its bottom is again sent to a naphtha splitter where
heavy naphtha product (HCN) and light naphtha product (LCN) are
obtained.

Amine treating section

The absorber gas from the sponge absorber contains majority of H2S
resulting from cracking reactions plus CO2 entrained in regenerated catalyst
as inert. These acidic gases are removed from absorber gas before being sent
to refinery gas pool. To remove gases it is contacted with a 25% wt. solution
of diethanol amine (DEA) in absorption tower 18C18. Entrained liquids are
separated in a knock out drum prior to this. Lean DEA solution from top tray
and sweet gas leaves from the top of the column, flows through wet gas
knock out drum 18B20 and is routed to battery limits. The rich DEA and
condensed liquid from knock out drums are flashed in another knock out
drum and sent to CO incinerator. The strippedH2S and CO2 are sent to SRU.

LUBE OIL BLOCK

47
 In lube oil block the reduced crude oil from the Atmospheric
Distillation Unit (ADU) is processed to produce lube base stock, slack wax,
transfer oil feed stock(TOFS) etc.

LOB contains the following ten units:

Name of the Unit Unit No. Unit Capacity

[TMT/YR]
Vacuum Distillation Unit (VDU) U 31 3790
Propane De asphalting Unit U 32 800
Furfural Extraction Unit U 33 515
Solvent De waxing Unit U 34 310
Hydro Finishing Unit U 35 225
Visbreaking Unit U 37 462
N-Methyl Pyrolidine (NMP) Extraction U 38 350
Unit
Wax Hydrofinishing Unit U 39
Catalytic iso dewaxing unit(CIDWU) U84 200

LUBE OIL (BASE STOCK) MANUFACTURING:

Lube oil base stock manufacturing is basically a series of different

secondary processing which a lube potent mother feed stock namely
Reduced Crude Oil undergoes.

As it appears, Reduced Crude Oil is the bottom of the barrel of basic

refining unit, Atmospheric Distillation Unit.

So the overall intricacy and complexity of operation does not lie on

individual processing unit but also managing the overall network in unison.

VACUUM DISTILLATION UNIT (U 31):

PURPOSE:
48
 • To Vacuum Distill RCO from Crude Distillation Unit.
• Vacuum Distillate is feed stock for LOBS units or FCCU.

PRODUCTS:
• Gas Oil ---- Diesel Component.
• Spindle Oil ---- Diesel Component or H-70 LOBS feed stock.
• Light Oil ---- 150 N grade LOBS feed stock or FCCU feed.
• Inter Oil ---- 500 N grade LOBS feed stock or FCCU feed.
• Heavy Oil ---- 850 N grade LOBS feed stock or FCCU feed.
• Vacuum Residue ---- Feed stock for PDA unit.

QUALITY MONITORING: K. V at 1000C, Flash Point, Density.

Capacity :1111200 T/year

FLUE
GAS

VACUUM GAS OIL

SPINDLE OIL

LIGHT OIL

REDUCED
CRUDE OIL INTERMEDIATE OIL

HEAVY OIL
MP STEAM

SHORT RESIDUE

VACUUM DISTILLATION UNIT

49
 Reduced crude oil from atmospheric unit or from tanks is the feed stock for
Vacuum Distillation unit. Reduced crude oil is preheated to 285 0C in
preheat exchangers and then to 4000C in the furnace. Steam is injected in the
furnace to achieve vaporization / prevent coking of the furnace coils. The
reduced crude oil then fractionated under vacuum in the column (31C01) to
obtain the following streams. A high vacuum condition and steam are
utilized to maximize the distillate recovery from reduced crude.

Streams Approximate boiling range TBP ( degree

C)
Gas oil 265-362
Spindle oil 362-385
Light oil 385-462
Intermediate oil 465-504
Heavy oil 504-542
Short residue 542+

Spindle oil, Intermediate oil, Heavy oil distillate and short residue are
further processed to produce lubricating oil base stocks. Gas oil, Light oil
and any surplus distillates are processed to saleable products.

PROCESS DESCRIPTION

Reduced crude received from the Atmospheric Distillation Unit or

from Intermediate Storage Tanks (T-701/702) is the feed stock for Vacuum
Distillation Unit. Reduced crude is preheated to 285 OC in a series of heat
exchangers and then it is partially vaporized by further heating in furnace
(31F1). The outlet temperature is controlled to maintain a flash zone
temperature of 400 OC. Steam is injected in the vacuum heater with the feed
and also introduced into the flash zone of the vacuum distillation tower. The
bottom liquid is steam stripped in the section below the flash zone.
Substantial quantities of steam in excess of that required for stripping is
required in the vacuum tower to reduce the partial pressure of the oil present
in the flash zone, to achieve required amount of oil vaporization at the flash
zone temperature of 400 OC. About 30% of the required stripping steam is
used as coil injection steam to prevent coking of the furnace coils. The vapor
leaving the flash zone of the vacuum tower passes through a demister pad to

50
ensure removal of entrained asphaltenes. Most of the hydrocarbon vapour is
condensed stepwise by top reflux as well as pump around sections and
fractionated to produce five liquid side draw products. Some uncondensed
and entrained gas oil with steam leave the top of the column and enter the
vacuum system. The gas oil and the steam are condensed in surface
condensers. The condensed oil is removed from the hot well and separated
from water in separator (31B3).

Spindle oil, Intermediate oil and Heavy oil are provided with steam
stripping facility. These products are routed to individual storage tanks.
Excess quantities of these products are routed to Fuel oil, Visbreaking Unit
and to internal fuel oil respectively. Unstripped light oil goes to either
Visbreaking Unit or to fuel oil storage tanks. Light oil can also be routed to
T-761. Short residue drawn from the bottom of the tower is sent to PDA and
Visbreaking Units storage tanks. A small quantity of hot short residue is also
routed periodically to Bitumen Unit and to TPS whenever required.

All products are cooled before sending to storage tanks by

exchanging heat with feed and water in the coolers. Short residue feed to
Bitumen Unit is sent hot after 31E11 or after 31-H-1a, b.

Vacuum in the tower is maintained by a set of booster and ejectors

with surface condensers. The vapor leaving the top of the tower is taken into
primary ejectors via pre condenser E128A/B from the two overhead vapor
lines. The non-condensable gases from E128A/B are successively passed
through inter condenser E129 and secondary ejectors. The secondary
ejectors exhausts non-condensable after passing through condenser E130
directly to the atmosphere through a vent system via water seal pot B107.
Operating conditions :
a) Feed inlet temperature ⇒ 286 OC
b) Feed outlet temperature ⇒ 400 OC
Vacuum column :a) Flash zone pressure ⇒ 100-125 mm Hg.
b) Flash zone temperature ⇒ 380 OC
c) Top pressure ⇒ 60-80 mm Hg.
d) Top temperature ⇒ 80 OC
e) Recycle to head temperature ⇒ 375 OC
51
 f) Column base temperature ⇒ 350 OC
g) Stripping stream flow rate ⇒ 6780 m3/hr.

Vacuum
To Ejectors

Capacity
• Rated -270 m3/hr •Top Temp:70-80
•top pres: 60-75
•Normal- 200-250 m3/hr •mmHga

Vacuum
Column
Objective:
PROPANE•To Draw Gas oilUNIT
DEASPHALTING range ( UNIT NO – 32):
Distillates & Lube
This unit produces deasphalated oil (DAO) by removing asphalt from
short residue Distillates by Vacuum
obtained from Vacuum Distillation Unit (VDU). Solvent
extraction process is chosen for removal of asphaltic material from short
Distillation
residue and deasphalted oil (DAO) is recorded. Propane is used as solvent
and its properties near the critical temperature are required.

Deasphalted oil is sent to Furfural Extraction Unit (FEU) for further

RCO
processing as bright stocks.
• Ex HS & LS crude
•Ex Tk 701/702/716
•Temp 402 deg C52
•pressure 130mmHga
 Asphalt is sent as fuel to TPS and as feed stocks to Bitumen and
Visbreaking units.

SHORT
RESIDUE
MIXING
PROPANE STEAM
TANK SOLVENT

EVAPORATION
PROPANE
TOWER
VESSEL
H.E. EXTRACTION
TOWERS
COOLER STEAM+SOLVENT
S
O
L
V
ASPHALT + LITTLE
E
AMOUNT OF SOLVENT
N
FURNACE
T
KO STRIPPER
Po STEAM+SOLVENT
t EVAPORATION
TOWER
VM STEAM

DE ASPHALTED OIL
(TO RUNDOWN
TANK)
STRIPPER
VM STEAM

ASPHALT (TO STORAGE)

PROPANE DEASPHALTING UNIT (UNIT-32)

PROCESS DESCRIPTION:
Extraction: The short residuum charged is mixed with propane
extraction tower. Feed enters the extraction tower and the solvent is pumped
into the bottom of the extraction tower. The heavy short residuum charge
flows downwards while the light solvent flows countercurrent upwards.

53
Solvent recovery: The DAO-solvent mixture flows from the top of
the extraction tower and the asphalt mixture is withdrawn from the bottom.
DAO-solvent mixture flows under pressure control from top of the tower to
the solvent evaporators 32C03 and 32C04 after getting heated through
exchangers. The major position of solvent is evaporated here. Both
evaporators are maintained at the required pressure level so that the
vapourised solvent flows directly to the solvent condenser.

The remaining amount of solvent in DAO is stripped off in the tower

32C06 by means of steam . The steam and solvent vapours pass overhead
and DAO products. The steam and solvent vapours pass overhead and DAO
products are pumped from the stripper bottom by 32P04 and level is
controlled through a stripper. Asphalt solvent mixture is taken from bottom
of the tower 32C01 under level control. The mixture is heated to about 225
O
C in the furnace F1 in order to vapourise most of the solvent and to prevent
foaming in the flash tower. Vapourised solvent is separated from asphalt in
flash tower C-2.

Solvent specification:

Name of component Weight

Propane 97.5
Ethane 1.0
Butane By difference

Operating Variables: Operating Variables and their effects are

described below. The ROSE (Residuum Oil Super Critical Extraction)
extraction column temperature and pressure gradient and solvent feed ratio
are the most important among them.

1. Extraction temperature and temperature

gradient

Above 380 C propane has a negative temperature co-efficient in respect

of asphalt and resin solubility. The top and bottom temperature are
maintained at 680 C and 520 C respectively. These temperatures are raised
depending on the feed stock and product quality that are desired. Increasing
the top temperature will precipitate and further quantity of asphalts of

54
gradually lower molecular weight. Feed temperature affects the top
temperature to some extent. The bottom temperature is maintained constant
by maintaining the solvent entry temperature for a steady degree of
extraction.

2.Temperature of the evaporator and stripper : Top

and bottom temperature are maintained in such a way that all propane and
steam escape from overhead but no oil vapor should go with them.

3. Extraction tower pressure: Higher the pressure is

sharper the separation. Pressure is maintained at 40 kg/cm2, so that the
solvent will remain in the liquid in the operating temperature.

4. Evaporator stripper pressure: Proper pressure gradient is

maintained between C-3 and C-4 so that the liquid flow can be smooth. The
pressure in the evaporator column will depend upon the pressure in propane
condenser E-6. The pressure in the stripper and condenser should be
sufficiently low for maximum solvent recovery.

5.Solvent feed ratio : Solubility of asphalt and resins in lower

paraffinic hydrocarbons increases in the order C-4, C-3, and C-2. Solvent
composition is maintained for steady product quality.

OPERATING CONDITIONS :

1. Extraction Column :
Short residue feed flow rate ( Mt/hr.) - 4
Temperature ( OC ) - 130
Solvent ( Propane ) flow rate ( Mt/hr.) - 283
Ratio of Propane/Feed - 6.3 by wt.
Temperature ( OC ) - 53
Operating temperature - Top ( OC ) - 68
Bottom ( OC) - 52
Operating pressure , kg/cm2 - 40

2. DAO Evaporator columns C-3:

i Operating temperature ( OC ) ---- 67
ii Operating pressure ( kg/cm2 ) ---- 23
55
 iii Feed flow to column ( Mt/hr.) ---- 274.2
iv Feed solvent / DAO ratio ---- 15/1

3. DAO Evaporator columns C-4:

i. Operating pressure , kg/cm2 --- 21
ii Operating temperature in OC
• Feed - 90
• Top - 190
• Bottom - 150.6
iii. Feed flow , Mt/hr. - 93.6

4. DAO Stripper columns C-6:

i. Operating pressure , kg/cm2 --- 1.7
ii Operating temperature in OC
• Feed - 144
• Top - 144
• Bottom - 149

5. Asphalt Heater F-1:

i. Flow to heater , Mt/hr. - 53.3
ii. Temperature ( OC )
• Inlet - 52.0
• Outlet - 67.8
iii. Pressure ( Kg/cm2 )
• Inlet - 34.0
• Outlet - 22.0

6. Propane Condenser E-6:

Operating Pressure ( kg/cm2 ) - 21.0

7. Propane Condenser E-7:

i. Flow of propane vapour , Mt/hr. – 2.7
ii. Temperature ( OC )

56
 Propane De-as

Capacity
• Rated -100 m3/hr
•Normal- 50-80 m3/hr

Short residue
•Visc @ 100 deg C: 1000+
•flash point
FURFURAL deg CUNIT
EXTRACTION :300+
(UNIT33):

•density
FEED STOCK:@Vacuum
15 deg Cfrom
distillate : 1.03
VDU & DAO from PDA unit.
Extractor
•Tk-706/718
PURPOSE: To extract aromatics from distillates to improveColumn
VI of
LOBS using Furfural as solvent.

PRODUCTS: Raffinate for further processing of LOBS and aromatics

extract.

QUALITY MONITORING:
Propane
Raffinate: KV @ 100oC, RI, CCR.
Extract: Density.
•density @ 15 deg C : 0.53

Objective:
•To produce feed
57 stock

for production of Bright

 TO
ATMOSPHERE
RAFFINATE
FEED
STOCK DE-AERATOR

FURFURAL
VM
STEAM

EXTRACTOR

FURFURAL
EXTRACT
EXTRACTION UNIT
(UNIT- 33)

The Furfural extraction unit includes the following sections:

1. De aeration
2. Furfural Extraction
3. Raffinate separation
4. Extract separation
5. Solvent recovery
• from raffinate solution
• from extract solution
• from water-furfural & furfural-water mixture
6. Neutralized with Na2CO3 solution

One of the important characteristics of lubricants is the viscosity

temperature relationship i.e. viscosity index. Viscosity plays a vital role in
the lubrication of moving part of machine. Temperature increase in most of
the applications are inevitable, viscosity tends to decrease, thus affecting the
performance. A good lubricant should have viscosity variations within
specified limits. A higher V.I. denotes less variation and such lubes are used

58
in places where either temperature variations are high or viscosity
specification is very straight.

The low V.I. is due to presence of aromatics in the stock and can be
improved by extracting out aromatics. Furfural is a good solvent for this
purpose.

The process is liquid-liquid extraction, where the extract phase is

automatic-rich oil plus major quantity of solvent and the raffinate phase is
comparatively paraffinic oil plus solvent.

Solvent is recovered from the two phases by heating, flushing and

stripping. Raffinate is routed to dewaxing unit for onward treatment while
extract is either blended in F.O. pool or sent as Carbon Black Feed Stock.

The solvent power and selectivity: The activity of a solvent to

keep the hydrocarbon component in solution is called its solvent power. For
the given hydrocarbons feed and at fixed solvent/feed ratio, solvents that can
hold more of selecting hydrocarbons in solution can be termed as solvent
with high solvent power.

Selectivity of a solvent indicates the degree of performance with which a

component or a group is dissolved in it to from a mixture.

Best solvent properties:

• High solvent power

• Low light-heavy selectivity and high group
selectivity
• Much different B.P. from that of feed stocks
processed
• Low melting point
• Density of 1.0 to 1.2 gm/cc
• Low surface tension
• Low toxicity
• High thermal/chemical stability
• Low flammability
• Low corrosively
• Low latent heat and specific heat
• Low viscosity at working temperature

59
 • High bio-degradability

The temperature affects the operating parameters in a solvent

extraction process. Hence, an optimum temperature is selected for
economic operation.

The effect of pressure is not appreciable extract for keeping

liquids in liquid phase only. A higher pressure also helps in clearer
separation.

Solvent feed ratio is very much important parameter. A high ratio leads
to better extraction but increase the operation costs.

PROCESS DESCRIPTION
1. De aeration section: Distillate oil is taken from the
storage tanks and pumped using 33-P1-1/1R through heat exchangers 33-
E-1A/B ( distillate oil vs. de aerator bottom ) and then through feed-steam
heat exchangers 33-E-2A/B ( distillate oil vs. extract rundown or extract
recycle ) and thereafter enters the de aerator column 33-C-1 . An absolute
pressure of about 150 mm Hg. is maintained in 33-C-1 using ejector or
condenser.

2. Furfural extraction section: De aerated distillate

oil is pumped through a charge cooler and then enters the extractor in which
two phases are formed . The raffinate with low content of furfural is
discharged at the extractor top and the extractor is discharged at the bottom .

3. Raffinate separation: The raffinate enters a vessel 33-

B-1 provided with an inert gas blanket from where it is pumped through heat
exchangers and heated in furnace 33-F-1 from where it is discharged at 220
O
C.

4. Extraction separation section: From the

extractor the extract is pumped through a series of heat exchangers,
temperature rising to 91 OC . A part of the furfural section is eliminated in
the bottom portion of the extract pressure flash tower and the rest is heated
to 230 OC in the extract furnace and then enters the extract pressure flash
tower at the top .

60
 5. Solvent recovery from raffinate
solution : The solution at 220 OC enters the raffinate flash tower at
150 mm Hg. Furfural vapors discharged overhead at 114 OC enters the
cooler operating at 100 mm Hg from, where liquid furfural is pumped at 60
O
C is pumped into the extractor .Temperature at the top of the raffinate flash
tower is maintained by furfural reflux . The raffinate solution from the
bottom of the raffinate flash tower is steam stripped. Furfural vapor and
water vapour and water vapor discharged from the top at 70 OC pass through
a cooler at 60 OC and then through a cooler at 60 OC and then through a
vessel provided with an inert gas blanket.

6. Solvent recovery from extract solution:

This is done in two stages:
a. Furfural vapour from the extract pressure flash tower at 180 OC are
cooled in drying solvent tower to 165 OC . The furfural vapours discharged
from the top of the extract pressure flash tower (operates at 2-7 kg/cm2)
enters the drying solvent tower via heat exchanger.

b. From the bottom of the extract pressure flash tower the extract
solution containing a low quantity of furfural passes into extract vacuum
flash tower at 150 mm Hg. from where furfural vapour is at 114 OC and
passes into cooler . The extract still contains furfural and is steam stripped.
From the bottom of the extract vacuum flash tower, furfural is pumped from
the extract
( at 168-192 OC ) to steam generator from where it goes to storage
tanks.

OPERATING VARIABLES

• Solvent/ Feed ratio: better raffinate and lower yield with increase in
ratio.
• Rotating Disc Column Speed: low speed- not enough contact.
High speed- inter mixing and bad phase
separation.

• Interface level: on increase in interface level, lowers the extraction

zone, yield and quality. Decrease in interface level, decreases
stripping zone and also lowers the yield.

61
 • Top and bottom temperature: Top temperature should be
maintained at 10OC less than CST.
• Extract recycle to bottom: Recycle reduces solubility of desirable
components. Increased recycle leads to higher yields but lowers
quality of raffinate.
• Water in furfural: the presence of water reduces solvent power.
• Oxidised Furfural: It contains acids, polymers and resins and leads
to fouling and corrosion.
• High Temperature operation of furfural: if the temperature is >
232oC, furfural decomposes, polymerizes and coke deposits.

The temperature affects the operating parameters in a solvent

extraction process. Hence, an optimum temperature is selected for economic
operation.

The effect of pressure is not appreciable except for keeping liquids in

liquid phase only. A higher pressure also helps in clearer separation.

Solvent feed ratio is very much important parameter. A higher ratio

leads to better extraction but increases the operation costs.

62
 Furfural Ext

Capacity
• Rated -60-70 m3/hr
•Normal- 50-70 m3/hr

Furfural
•density @ 15 deg C : 1.15
SOLVENT
•B.PDEWAXING
: 162 deg UNIT
C (UNIT-34):

Feedstock: Raffinate from furfural extraction unit. Extractor

Product: Column
LO Dewaxed oil & Slack Wax.

Quality•density @ 15 deg 0.90

Monitoring:
IO
DWO: Pour point, Flash point, KV @ 100oC & 40oC
Slack Wax: Flash Point.
•density @ 15 deg 0.93
HO
Feed of this unit is the distillate obtained from VDU either directly or after
processing density
the same in @ 15 Extraction
Furfural deg C :Unit. 0.94
DAO
Either of the following is used as solvent.
•density
1. Bright @stock
15(HVI,
degLVI).
C : 0.93
2. Heavy Neutral (HVI, LVI).
3. Intermediate Neutral (HVI, LVI).
4. Spindle Oil (HVI, LVI).

63

Objective:
Objective: Objective of solvent Dewaxing Unit is to remove paraffinic
hydrocarbons of the extract to bring down the Pour Point Value in lube base
stock. In that case, it will be suitable for low temperature applications.

Theory: Dewaxing is a complex process in which extraction and

crystallization followed by filtration occurs. The solvent blended extracts the
lube oil (which is desired product) is crystallized from and the wax (i.e.,
undesired part) is collected from a two phase mixture of MEK and toluene.
In Haldia Refinery toluene is used as solvent to dissolve the desired
component of feed stocks.

Antiwax Solvent: Antiwax solvent, also called wax-rejecter (MEK)

is use to avoid solubility of wax in oil solvent i.e., toluene. MEK is useful in
this purpose for its poor oil miscibility character. Toluene and MEK should
be blended in such a way so that it imposes highest solvent effect on oil and
little solvent effect on wax.

Oil Miscibility Temperature: Oil miscibility temperature is

the lowest temperature of the blend which without any problem can be used
Dewaxing purpose. Below this OM temperature a second oil phase which is
rich in wax generates in addition to oil in solvent and wax phases. To avoid
it, the dewaxing temperature is kept above oil-solvent miscibility
temperature for the given solvent blend and feed stock. Otherwise the
filtration becomes more erratic, wax contains more oil and also Pour Point of
oil will be affected with increase in MEK in the blend.

Crystallization: This process takes place with nucleation and

growth. It is a very complex process in which both mass and heat transfer
takes place in a multicomponent system like wax.

The size and shape of wax crystals are affected by:

1. Nature of feed stock.

2. Hydrocarbons composition.

Normal paraffin = Plate type crystal

Isoparaffins = Needle type crystal

Napthenes = Microcrystalline
64
Boiling ranges of the feed stock: As boiling range
increases, its viscosity increases and composition changes from n-paraffin to
iso-parrafins and napthenes. Again if viscosity increases more solvent is
required for dilution which is necessary for crystallization and to reduce the
precooling in chiller.

Rate of chilling: Faster/sock chilling results finer crystals which

clog the filter medium and also carry more oil into crystal lattices.

Mode of solvent addition: Minimum solvent dilution at the

time of nucleation provides the few nuclei of wax crystal and gives the best
crystals for filtration. Wax cycle growth is also benefited by low
concentration of initial dilution as well as long residence time in chillers.
Low initial dilution concept is not applicable for

high viscosity /high Pour Point feed stock but applicable and useful for
medium/low viscosity stocks.

Viscosity of crystalline media: The viscosity of media must

be favorably low and uniform to keep the crystal size distribution to a
limited range that would give good filtration rate.

PROCESS DESCRIPTION
The unit is subdivided into the following sections:
• Feed solvent recovery section.
• Ammonia chilling section.
• Filtration section.
• Solvent recovery section.
• Refrigeration section.

Feed solvent recovery section: The molten waxy feed is

mixed after primary dilution in various proportions depending on the grade
and viscosity of lube raffinate. The solution is first heated in a steam heater
to homogenize the feed mixture 5-10oC above its cloud point. The solution is
cooled under controlled condition first in water cooler to the nucleation
temperature then in a tank of scrapped surface exchangers and chillers
employing cold filtrate and liquid ammonia as cooling medium respectively.

65
Ammonia chilling section: Feed mixture stream before joining
from two feed streams into one are cooled to a temperature just above the
cloud point to ensure that crystallization will start only in DP exchangers.
The feed mixture is then distributed into seven parallel trains with each train
comprising of two double pipe scrapped surface exchanger (LR) followed by
three DP chillers (LR) in series.

The secondary dilution is added at set temperature to each train at the

out first DP chiller or at the first DP chiller. The exact location of secondary
of solvent injection point can be varied and is chosen for different feed
stocks as required.

Filtration section: The feed mixture stream after further chilling

in third DP chiller of each train are joined and are routed to the filter feed
drum. The territory dilution solvent is added before it goes to filter feed
drum. The solvent train is joint to both streams and used where it is
necessary.

The chilled feed mixture in the form a slurry of wax crystal in oil and
solvent flows by gravity from filter feed drum which is blanked with inert
gas and is distributed to ten parallel filtration trains. The filter drum carrying
filter media is submerged and rotates in the filter vat filled with the chilled
slurry of dewaxed oil solvent mixture containing suspended wax crystal.
Inert gas vacuum compressor produces the vacuum. As the wax cake is
formed on the filter cloth the cold solvent at the filtering temperature washes
it continuously. After the cold washed zone, the inert gas is drawn through
the filter cloth in order to dry the cake. Blowing the chilled inert gas from
inside the filter cloth then dislodges the washed cake. A doctor blade is
gently removed the cake over to a rotating scroll conveys it to the filter boot
(34-B-3). A steam coil in the filter boot heats up the wax mixture. The wax
mixture is pumped by filter boot pumps to slack wax solvent recovery
section. The dewaxed oil (DWO) mixed filtrate and the inert gas from
filtrate receiver flows to inert gas drum to eliminate any entrainment before
it enters to the inert vacuum compressor.

Solvent recovery section: The DWO mixture is heated and

vapourised by the overhead vapour from the DWO first flash column (34-C-
1) and DWO second flash column (34-C-2) by 34-E-5 A/B and 34-E-7
A/B/C/D exchangers. The bottom liquid is fed to second flash column (34-

66
C-2). The overhead solvent of 34-C-3 vapours go for solvent drying (34-C-
10) where bottom liquid of 34-C-3 flows by gravity to 18th tray of DWO
stripper (34-C-4). In DWO stripper superheated low pressure stream is
introduced at the bottom to remove the remaining solvent from the DWO.
The product DWO from 34-C-4 column, bottom is routed to storage.

Refrigeration section: The refrigeration section consists of three

basic cycles compression, liquefication and evaporation. It is a closed circuit
system.
Ammonia vapour rescued from the cooler, chiller, heat exchangers are send
to the refrigeration section for the two cooling stages at –15 oC and 30 oC
respectively. The plant is equipped with two centrifugal compressor for
compression of such vapour.

OPERATING PARAMETERS

Boiling ranges of the feed stock: As boiling range increases its viscosity
increases and composition changes from n-parrafin to iso-paraffins and
napthenes. Again if viscosity increases more solvent is required for dilution,
which is necessary for crystallization and to reduce the precooling in chiller.

Rate of chilling: Faster/sock chilling results finer crystals, which clog the
filter medium and also carry, more oil into crystal lattices.

Mode of solvent addition: Minimum solvent dilution at the time of

nucleation provides the few nuclei of wax crystal and gives the best crystals
for filtration. Wax crystal growth is also benefited by low concentration of
initial dilution as well as long residence time in chillers. Low initial dilution
concept is not applicable for high viscosity/high Pour Point feed stock but
applicable and useful for mediem/low viscosity stocks.

Viscosity of crystalline media: The viscosity of media must be favorably

low and uniform to keep the crystal size distribution to a limited range that
would give good filtration rate.

Rate of agitation: The constant motion of solution keeps a steady growth of

crystals. Absence of agitation would lead to decomposition of wax crystals
on internal surface and affect the performance.

67
Oil Miscibility Temperature: Oil miscibility temperature is the lowest
temperature of the blend that without any problem can be used for Dewaxing
purpose. Below this OM temperature a second oil phase, which is rich in
wax, generates in addition to oil in solvent and wax phases. To avoid it, the
dewaxing temperature is kept above oil-solvent miscibility temperature for
the given solvent blend and feed stock. Otherwise the filtration becomes
more erratic, wax contains more oil and also Pour Point of oil will be
affected with increase in MEK in the blend.

Solvent De-

Capacity
• Rated -20-55m3/hr
•Normal- 10-25 m3/hr

De-Waxed Oil Vacuum

•IN DWO Tk712,714,851,853 Pulling
HYDRO FINISHING UNIT(UNIT – 35):
•BN DWO Tk 716
PURPOSE: To improve color of lube base stocks by removal of
•LN DWO Tk 713,852
sulphur, oxygen and nitrogen in a reactor with Co-Mo catalyst.

FEEDSTOCK: DWO from SDU.

CATALYST: HR 348 supplied by Procatalyse. High purity alumina

extrudates impregnated with Ni-Mo oxides.

68
QUALITY MONITORING: Color, KV @ 100oC, VI.

The aim of the hydro finishing unit is to improve the color and the color
stability of Lube Base Stocks.

The process is a mild hydro treating one, using a catalyst made of sulphide
from Group-VIII and VI A of periodic elements table, combined with non
acidic carriers e.g., ones of the alumina type

69
 AMINE SOLVENT
DWO OIL
FEED
FURNACE

HYDROGEN
GAS AMINE
ABSORBER
COMPRESSOR CATALYTIC
REACTOR
R
I
C
SEPARATOR H
OFF GAS
A
M
I
N
E

H2 GAS

STRIPPING
COLUMN
K.O. DRUM

SOUR WATER
DRAIN
STRIPPING REGENERATED AMINE
COLUMN

STRIPPING STEAM

PRODUCT

HYDRO FINISHING UNIT (UNIT-35)

Many reactions are involved during hydrofinishing and we can distinguish

the following:
1. Hydro-desulphurisation.
2. Mild hydro-denitrogenation.
3. Olefins hydrogenation.
4. Mild aromatics hydrogenation.

70
 5. Decomposition of other hetero molecules such as
oxygenated compounds.
As a result of all these reactions the colour and the colour stability of
the lube-based stocks are improved. The overall performance can be
connected with the hydrodesulphurisation performance.

PROCESS DESCRIPTION:

The following chemical reactions are involved:

1.Desulphurisation: The sulfur is present in the feed under

various forms such as mercaptans, sulphides, disulphides and combined
form in cycles with aromatic character (thiophenic sulphur).
The decomposition of sulphur compounds are illustrated here after:
Mercaptans ⇒ RHS + H2 = RH + H2S
Sulphides ⇒RSR' + 2 H2 = RH + R'H + H2S
All these reactions produce H2S consuming H2 and are exothermic. In
hydrofinishing required reactions are mainly the desulphurization of
sulphides, disulphides, mercaptans and partly of some sulphur combined
form in such a way that some aromatic compounds with sulphur remain in
the lubes. These compounds act as antioxidants and allow additive economy.

2.Mild hydro-denitrification: Nitrogen is contained

essentially in heterocyclic compounds. When hydrofinishing raffinates, a
large part of undesired nitrogen compounds are removed at previous
treatment which is solvent extraction.
Nevertheless, for some typical highly nitrified crude some hydro-
denitrification is required in hydrofinishing for reaching better colour
stability.
Amines ⇒ RNH2 + H2 = RH + NH3
The ultimate products of hydro-denitrification are hydrocarbons and
ammonia.

3.Hydrogenation of olefins: Some olefins can be present in

the raffinates but generally in low quantity. Most of them are saturated
during hydrofinishing reactions. The corresponding measurement is the
Bromine Number Value.

71
4. Very mild hydrogenation of aromatics: Normally
in the hydrofinishing aromatics is not hydrogenated. Nevertheless, the
analysis shows a slight decrease in aromatics in the stripped oil (the finished
oil). This decrease is partially due to liberation of some aromatic rings
towards the light compounds which are stripped to reach the required flash
point.

5.Decomposition of oxygenated compounds and

other reactions: Generally, the oxygenated compounds are mostly
removed at the solvent extraction step. If still any, they will be removed with
hydrofinishing.
The unit can be divided into two distinct sections viz.,
1. Reaction section.
2. Stripping section.

In the first section the reactions mentioned above is effected under

controlled conditions while the second section describes the removal of the
reactants, gas, etc. from the finished Lube Base Stocks.

Reaction section: Lube oil from storage tank is fed to the unit by
feed pump 35-P-01 A/B. The feed rate is controlled by 35-FRC-03.
Hydrogen rich gas is a mixture of makeup gas boosted by hydrogen makeup
compressor 35-K-01 A/B and of recycled gas boosted by recycles
compressor 35-K-02 A/B/C. The flow of makeup gas is controlled by 35-
PRC-01 acting on compressor by-pass, which allows maintaining a constant
pressure in the suction drum of compressor 35-B-01. The makeup
flow is recorded on 35-FR-02. The lube oil feed and hydrogen gas are
mixed, preheated by drier (35-C-03), bottom is exchanger 35-E-06
(shell side) they by exchanges with the reaction effluent is exchangers 35-E-
1 A/B/C (shell side).

During the above operations the effluent is sent directly to atmosphere

at high point provide for the purpose. The reactor effluent from 35-R-01
gives up heat to the reactor feed in exchangers 35-E-01 A,B,C (tube side)
before flowing to the high pressure separator drum 35-B-02. The required
temperature of 35-B-02 is controlled by 35-TRC-01 which regulates
the by-pass reactor feed around exchanger 35-E-01 by acting in 3-way valve
35-TRCV-01. The reactor effluent is subsequently flashed in the first high
pressure separator 35-B-02 at high temperature (at least 200 oC). The liquid

72
from 35-B-02 flows to the low pressure separator 35-B-04 (at high
temperature) under level control 35-LIC-02.

The vapour from 35-B-02 is cooled in the water cooler 35-E-02 and
flows to the second high pressure separator drum 35-B-03 at low
temperature (50 oC). The liquid from 35-B-03 goes to low pressure separator
under level control 35-LIC-03.

H
Lube
(H2 separ
PC-04
To fuel ga

E-7

CW
B-4 B-8
From B-2 / B-3
bottom

VISBREAKING UNIT (UNIT – 37)

Rightly viscous heavy oil products can be converted into lower viscous oil
products by means of a thermalLC-06 process called Visbreaking (Viscosity
Breaking). The main purpose of the unit is cutting down the viscosity and
pour point of heavy residues, which constitute a stable fuel oil component.
Gas and stabilized gasoline are also obtained.
#15

C-2

Stripping steam #1

73LC-08
 VISBREAKER NAPTHA

GAS OIL QUENCH

GAS OIL

FEED
FRACTIONATOR
FURNACE

VB TAR (FOR FURTHER

SOAKER PROCESSING)

VISBREAKER

VISBREAKER UNIT( Unit-37)

The feed has the following characteristic:

Viscosity at 100 oC = 5.05 c.p.
Pour point = 27 oC
Gas, gasoline and visbroken tar are the products of this process. Amine
regeneration unit, Kero-HDS unit and hydrofinishing unit are all burned in
the flare which was the main problem for decreasing air pollution so the
installation of this unit became necessary. All the H2S from the units are
recovered as elemental sulphur (about 99.9%). The design intention of SRU
is to recover sulphur from the feed and to allow a maximum of 10 ppm of
H2S in the final flue gas going to the stack.

74
 Soaker Visbr
Capacity
• Rated -70 m3/hr
•Normal- 55-70 m3/hr

Objective:
•To reduce the viscosity of
feed stock by mild
Thermal Cracking. Fractionator

Asphalt +SR +LO + SO

•visc @ 50 deg C: 1000-
30000
•temp 445 deg C
•pressure : 5-6 kg/cm2

75
NMP EXTRACTION UNIT (UNIT- 38)

KNOCK OUT
POT

CBD
FEED

DE-AERATOR
SOLVENT RAFFINATE
NMP (12-20%
SOLVENT)
STEAM

EXTRACTOR

EXTRACT
(78-83%
SOLVENT)

TO VACUUM
CONDENSATE
DRUM
NMP EXTRACTION UNIT (UNIT-38)
VACUUM
FLASH
COLUMN
TO SOLVENT
DRYER

EXTRACT
STRIPPER
STEAM

EXTRACT R/D

76
The solvent used for extraction is NMP i.e., M-Methyl Pyrolidone. The unit
handles 3 major streams extract, raffinate and water. The solvent recovery
from both extract and raffinate phases is carried out in such a ppm level. The
water vapour leaving drying column (38-C-10) is routed through the de
aerator (38-C-01) and the contaminate NMP (if present) is absorbed by the
feed meeting stream countercurrently.

PROCESS DESCRIPTION:
The unit typically consists of the following section:
1. De aeration/extraction section: Objective of this section is to remove
dissolved air in feed. Though NMP is thermally stable, dissolved air will
accelerate its degradation. This is done in 38C01 through stripping steam.
Objective of the extraction system is to extract out condensed
aromatics and polar compounds from feed, to improve color, VI, flow
characteristics of feed stock. This is done in 38C02, which is a 7 bed packed
tower.
2. Raffinate recovery section: it separates raffinate from raffinate mix
by vacuum flashing and steam stripping after heating in a raffinate mix
furnace.
3. Extract recovery section: it separates solvent and extract from extract
mix by carrying out flashing at different temperatures and pressures and
finally stripping with steam at pressure below atmospheric.
4. Solvent drying section: to remove water coming along with solvent
recovered at different recovery stages to a desired level of water in the
solvent to be used as solvent in the solvent extraction column and as reflux
in various section.
5. Solvent utility/conservation section.

De aeration/extraction section: The charge oil from offside

is pumped through the charge pump to de aerator (38-C-01) after heating to
110 oC through the de aerator feed preheater. Stream heater 38-E-01 located
downstream of 38-E-01 A/B is used to heat the de aerator feed during
startup. Dissolved air in feed is stripped out by L.P. steam coming from
solvent drying column (38-C-10). The solvent is pumped from the bottom of
the solvent drying column (38-C-10) by solvent charge pumped (38-P-05
A/B) to the top of the extractor under flow control.

77
The oil sprayed in the extractor rises through the tower as droplets and meets
the continuous phase, following the oil and the solvent a counter current
flow between solvent passing through the packed beds dissolves aromatics
mainly condensed and polymeric aromatics. The solvent rich extract phase
leaves the bottom of the extractor column to the extract recovery section
under interphase level control maintained at the top section of the extractor.
The hydrocarbon phase having mainly non-aromatics components (paraffins
and napthanes with considerable amount of monoaromatics) leaves the top
of the column as raffinate mixture with about 12-20% solvent.

Raffinate recovery section: The raffinate mixture from the

top of the extractor is subjected to solvent recovery. It is collected from the
extractor top and then collected at the raffinate mixture drum (38-V-01). The
raffinate mix which is heated to about 271 oC in the natural draught raffinate
mix heater (38-F-02) is then flashed in the raffinate mix flash column (38-C-
03) operated at 0.16 kg/cm2 abs. Then it enters the raffinate stripper (38-C-
04) under flow control. The solvent vapour leaving the column top (38-C-
03) is condensed in the exchanger (38-E-04) and water cooler/condenser
(38-E-24) and it is sent to the vacuum flash condensate drum (38-V-05).
From 38-V-05 the condensed liquid is finally pumped to the solvent drying
column 38-C-10.

Extract recovery section: Separation of solvent from extract

mixture having solvent content of 78-83 % is subjected to solvent recovery
in this section. The extract mixture from extract bottom (38-C-03) is
collected in extract mixture drum (38-V-06) is maintained by split range
controller with inert gas. The extract mixture from 38-V-06 is pumped by
pump to the flash column (38-C-05) through a series of exchanger.

Solvent drying section: The solvent vapours from L.P., M.P.,

and H.P. flash columns goes to the 5th tray (from bottom) of solvent drying
column 38-C-10. The condensed from extract vacuum flash column pumped
from vacuum flash condensate drum by vacuum flash solvent pump and fed
to the 7th plate of the solvent drying column (38-C-10). The condensate
(water) from solvent drying column accumulator drum (38-V-04) is pumped
by solvent drying column reflux pump to the 27th plate of the column at 55
o
C.

78
Solvent utility/conservation section: In acidic medium
NMP, in presence of air undergoes degradation. Besides, the de aeration of
feed and nitrogen blanketing in tanks, vessels and columns, the pit of the
solvent is controlled by neutralization, using sodium carbonate. The sodium
carbonate solution from sodium carbonate mixing pot (38-V-11) is injected
both to solvent drying column accumulator drum (38-V-04) and to the
extract mixture extract mixture solution drum (38-V-06) with sodium
carbonate injection pumps (38-P-14 A/B).

NMP Extra

Capacity
• Rated -47-56 m3/hr
•Normal- 40-50 m3/hr

NMP
•density @ 15 deg
WAX HYDROFINISHING UNIT C : 1.15
PURPOSE: To improve properties like color and color stability of
•B.P : 204 deg C
paraffins. Ca talysts allow hydrogenation of aromatics and removal of
sulphur and nitrogen. Oxygneated compounds that may be present will be
hydrogenated. The unit produces microcrystalline wax from de-oiled wax.
LOCONDITIONS:
OPERATING
Extractor
• Reactor•density @: 135.5/134
inlet/outlet pr. 15 degkg/cm2g
0.90 Column
• ReactorIO
inlet/outlet temp : 300 def C
•density
• Liquid Hourly space @ 15 :deg
velocity 0.93
0.25 hr-1

HO
79
density @ 15 deg C : 0.95
DAO
• Hydrogen Partial pressure : 100 kg/cm2g
• Hydrogen to Hydrocarbon mole ratio : >500
• Hot HP separator : 180 deg C/132 kg/cm2g
• Cold HP separator : 40 deg C/131.7 kg/cm2g
• HP Purge : 36 deg C/66 kg/cm2g
• LP Seperator : 185 deg C/6.0 kg/cm2g
• LP Purge : 40deg C/4.4kg/cm2g
• Liquid in to stripper : 185deg C/0.3 kg/cm2g
• Liquid MCW ex drier : 180deg C/0.082 kg/cm2g

Wax Hydro-fi

Feed: De-oiled BN wax

•Oil content: 2% max
•Ex TK -763

Hydrogen
•Purity: 80% vol
Rea
80

Capacity
CATALYTIC ISODEWAXING UNIT: (UNIT 84)

OBJECTIVE: To produce Group-II & III grade LOBS.

MAJOR REACTIONS: Hydrotreating, Catalytic Dewaxing &

Hydrofinishing.

FEED: 100N/ 150N/ 500N/ 150 BS & 500N raff & SL wax mixture &
500N slack wax.

THE PROCESS:
In this unit there are three reactors HDT, MSDW, HDF. In HDT the
waxy feed is hydro treated in order to remove impurities like sulphur,
nitrogen, oxygen which poisons the catalyst. In MSDW (Mobile selective
dewaxing) the wax is removed in presence of catalyst. In HDF the product is
hydro finished to improve its quality.

PROCESS DESCRIPTION:
Feed section: Waxy oil is first heat exchanged in heat exchangers
84-E-01.it is then filtered in oil feed filter. The feed is then passed to feed
coalescer from where after coalescing it goes to oil feed surge drum 84-B-
01.

Preheat Section: Feed is preheated in heat exchanger 84-E-02 with

HDF reactor effluent. The recycle gas is added to it. It is again preheated in
heat exchanger 84-E-03.Preheated feed is then heated in HDT reactor
charge heater. 84-F-01.

Reaction and product separation: Heated feed goes to

HDT reactor 84-R-01 where hydrotreating reaction takes place where
nitrogen is converted to NH3 while sulphur to H2S.Reaction is exothermic
in nature, so interbed quenching is done to maintain reaction temperature.
The reactor effluents are cooled in feed/HDT effluent heat exchanger 84-E-

81
03. To maintain feed temperature to stripper some portion is bypassed. This
partially cooled effluent is sent to HDT effluent stripper 84-C-01 where
phase separation takes place.H2S and NH3 are stripped from resulting liquid
phase using hydrogen make up gas.

Column bottom liquid is routed to MSDW feed /effluent heat exchanger 84-
E-06.A part of the liquid may b routed to raffinate stabilizer for stabilization.
Vapour from stripper 84-C-01 is cooled in HDT stripper overhead/feed gas
heat exchanger 84-E-04 and then air cooled in 84-EA-01while further
cooling is done in train cooler84-E-05.
It is then sent to low temperature seperator 84-B-02.There are two phases
liquid and vapour are separated. Vapour phase goes to amine and water wash
section for recycle gas purification and liquid goes to HP stripper. Vapours
from 84-B-02 are scrubbed with lean amine in HP amine absorber 84-C-02
for H2S removal. Overhead vapours from 84-C-02 goes to amine knock out
drum 84-B-03 and then to wash water column 84-C-03 for NH3 removal.
Rich amine from 84-C-02goes to amine degassing drum to flush off
dissolved gas and liquid goes to amine recovery unit. Sweetened vapour
from 84-C-03 is reheated in HDT stripper overhead/treat gas heat exchanger
84-E-04.

Preheated clean treat gas is then recombined with bottom liquid product of
84-C-01 which is heated in 84-E-06.Final heat to dewaxing reactor
temperature is achieved is MSDW reactor charge heater 84-F-02.

In MSDW reactor the paraffin in the waxy oil feed are selectively cracked
and isomerised in presence of hydrogen and MSDW catalyst to improve
feeds cold flow property. Reaction being exothermic so inter bed quenching
is required. MSDW reactor effluent are cooled in heat exchanger 84-E-06
against waxy feed and then it is charged to HDF reactor 84-R-03.Here the
contaminant in the oily feed are removed and most of the olefins are
saturated to improve product quality and stability. Reaction is mild
exothermic.

Low pressure recovery section: Liquid from LTS B-05,

HTS B-04 and HDT LTS B-02 are fed to HP stripper 84-C-04 for separation
of naphtha and light materials from dewaxed oil streams. Pressure letdown,
heat in HTS liquid and MP stripping steam to 84-C-04 bottom provided for
flashing and stripping. Overhead vapours are cooled and condensed in HP
stripper overhead condenser 84-E-12.Effluent from 84-E-12 is phase
82
separated in HP stripper overhead accumulator 84-B-10.Vapours from 84-B-
10 is contacted with lean amine in LP amine absorber 84-C-09 for H2S
removal, before discharging into fuel gas header under pressure control of
84-B-10.Unstabilised naphtha product is pumped from84-B-10 to distillation
unit for stabilization a portion of naphtha material is refluxed. Bottom
product from 84-C-04 is pumped to vacuum fractionator charge heater 84-F-
03 under level control..

In vacuum fractionator 84-C-05 distillate and lighter material are separated

from dewaxed base stock to avoid thermal cracking and degradation.
Distillation is carried under vacuum. Overhead vapour from fractionator is
cooled and condensed and sent to vacuum fractionator overhead accumulator
84-B-11 for phase separation. Part of the liquid, light distillate cut are
refluxed, balance of the liquid is pumped out as net product to refinery
storage tank.

To meet quality specification on the dewaxed base stock product a heavy

distillate cut is produced. This cut is steam stripped and vacuum dried in
heavy distillate stripper 84-C-07 and vacuum dried in heavy distillate drier
84-C-08. The heavy distillate product is pumped to cooler. Dewaxed based
stock product from bottom of 84-C-05 is vacuum dried in vacuum drier.

Catalytic De-w
Hydrogen
•Purity:98% Vol

Feed:
IN/BN/LN Raffinate

Capacity
• Rated –40.8 M3/hr
• Normal-20-25 83m3/hr
 OIL MOVEMENT AND STORAGE:
This unit plays an important role in the storage of imported crude brought by
tankers. Refinery storage tanks are used in storage of crude oil and finished
petroleum products. Products from these storage tanks are dispatch for
marketing by tankers, wagon, drums, cylinders etc.

The mode of dispatch depends on the distance to be traversed and on the

capacity of the pump. For the pumping of highly viscous oils, positive
displacement type pump are used where as in the case of non viscous oil
centrifugal pump are used.

The broad functions of OM & S are listed as follows:

i. Receipt and storage
• Crude oil from tankers
• Intermediate and finished products from process units.
ii. Preparation and supply of feed to various units
iii. Blending of products
iv. Despatch of products
v. Supply of fuel oil to furnaces
vi. Unloading, storing, supplying various solvents and chemicals to
units
vii. Recovery of steam condensate
viii. Accounting of petroleum products and observing necessary
customs and excise formalities
ix. Effluent treatment
In addition to the above , the following auxiliary functions are also
connected to the OM&S division :

a. Calibration of tank wagons and tanks

b. Cleaning/Steam flushing of tank wagons
c. Decantation/ trans-shipment of tank wagons and tank.

TANK FARM:
Types of tanks: Generally, the tanks used for storing petroleum
products are:
i) Fixed cone roof type
ii) Floating cone roof type

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 iii) Fixed cum floating roof type.

i) Fixed cone roof type tank:

These are used for storing low volatile products. They have a vertical
cylindrical structure with conical top made of welded steel. They are
provided with manholes on the shell and roof, products inlet and outlet,
ladder, gauging plate, gauging batch with reference mark, mechanical type
level gauge, open vent with wire mesh, earthling connections. They are also
provided with sampling devices, temperature gauge, and steam heating coils
etc. as per service requirement. The welded steel plate at the bottom of the
tank is placed on a specially prepared bed made of sand and bitumen.
Insulation is also provided in such tanks when hot fluids are stored.

In order to prevent the tank from collapsing, when the stored liquid is
being drained out a vent is provided at the fixed rooftop. The whole system
is earthen to prevent generation of static electricity .It also contains a flame
arrester. A breather valve is also provided to prevent air from into the
system while the liquid is being drained out .For this reason, the system is
blanketed with nitrogen.

iii)Floating roof type tank:

These tanks are used for storing highly volatile products. They are vertical
cylinder vessels having a roof, which normally floats on oil. In absence of
stored oil, it rests on its legs. The other accessories are similar to that of
fixed roof type. Haldia Refinery generally uses “Pontoon" type floating
roofs. Other possible forms are double deck and pan type.

iii)Fixed cum floating roof type:

These type of tanks are used to store unsaturated hydrocarbon solution.
From outside these tanks are looks like fixed roof tank. But there is floating
roof inside the tank. Nitrogen blanketing is there to prevent any kind of
explosion .Although several other design are also made according to the
needs tanks are provided with

a) Manhole on the shell and roof.

b) Product inlet and outlet nozzle.

c) Drains.

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 d) Staircase and ladder.

e) Mechanical type level gauge.

f) Open vane with wire mesh or Breather valve or vent with flame
arrest depending on the service the tanks are provided with

a) Sampling device

b) Temperature gauge

c) Jet mixing nozzle

d) Inert gas blanketing

e) Steam heating coils

Product is taken to this tank though the inlet by different pumps. There are
two outlet one for blending and product conveying and another for drainage.
Generally products from different units also contain some amount of water
with them. This unwanted water is drained through that outlet. Some other
important operation such as blending is also done by the outlets. In blending
different oil are mixed up to meet the specifications of the final product oils
such as Motor Speed Oils (MS), Diesel etc. Constant circulation of the
product of tank is done for better mixing through these outlets.

CALIBRATION OF TANKS: All tanks for storing petroleum

products are calibrated to have measurement of volume in terms of the level
of liquid in the tank.
This height is measured along the vertical distance between a reference mark
and the striking point on the tank floor, viz. datum plane. A calibration table
is prepared for liquid volumes inside the tank at various heights after making
allowance for the volume displaced by the roof supports and the submerged
portion of the pontoon ( for floating roof tanks only ) , heating coils and
other fittings inside the tank .
Generally, the tanks are calibrated as per ISI standard. Tanks are calibrated
by CPWD Engineers.
The measurement of petroleum involves three operations
i) Gauging the tanks
ii) Recording the temperature of the product
iii) Drawing a representative sample of the product.
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CRUDE OIL RECEIPT: Crude oil is received by the mode of water
transport through tankers from the following countries
i) Middle East countries viz. Iran, Saudi Arabia, Kuwait
ii) Russia
In the process, a carrier agent is present here it being “The Shipping
Corporation Of India Limited “. The cargo is received in two oil jetties; one
uses hosepipe and the other uses Automatic Loading Machine.
A part of the crude are taken from the port, which is called “Port Sample"

OPERATIONS: Crude oil received from tankers and after proper

setting and draining is fed to the crude distillation unit. Intermediate
products are received either by finished or semi-finished condition. Semi-
finished products are converted to finished products either by blending or by
further processing in other unit. Rail, road, sea/river, and pipelines as per
plan then dispatch them
.
Bitumen filling station:
Bitumen has two grades:
i. Industrial
ii. Straight

IOC Haldia produces straight grade only .The straight

grade can again be of three types depending on the penetration point. This
grade also has some classification viz. 80/100, 60/70, 30/40 etc. At a time
one particular type of bitumen is loaded into the tank. Bulk loading is done
separately for each grade of bitumen through dedicated lines.

The loading is controlled by several sensors which enable the empty drum to
be placed at the proper level below the discharge pipe,proper positioning of
the empty drum on the conveyor at the proper level below the discharge pipe
and the exact amount of bitumen to be filled into each tank.
A total of 18,000 MT/a of bitumen are produced in Haldia
Refinery. The capacity is likely to increase to 2,50,000 MT/a . Bitumen
filling station has been designed to fill 82,000 drums per month and works
for two shifts per day. The remaining is dispatched by tanks/trucks/wagons.

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NORMAL OPERATION:-

1. Check DM water level in steam drum.

2. Check steam pressure in steam drum.
3. Check inlet/outlet temperature of Bitumen &MP steam pressure.
4. 6Nos of semi automatic filling machines (Altus, Italy) are provided to
fill bitumen drum as weight controlled basis.
5. Filling empty drums to filling machine is done manually is a roller
conveyor.
6. Drum centering and positioning at the filling point is automatic.
7. Filling valve closing is automatic with cutoff point set at 156.5 kgs.
8. Removal of filled drum from machine plat from and feeding to power
driver roller conveyor is done manually.
9. Pressure filling is done through back pressure control valve with
controller 4 kg/cm².
10. There is an electric counter to count the number of drum fills.
11. Open mouth of filled bitumen drums are taken at 4Nos. of diverters by
chain conveyor, Forklift or jhumka there after take the said drum and
stack in storage yard.

a) Drum filling temperature oppose 100-120ºc.

b) Filling pump capacity -85cum/hr with 9 kg/cm²

12. Total time for filling of one drum including feeding

empty drums20-23seconds and removal of filled drum from machine
from platform.

Tank Truck Loading ( TTL ) : The tank truck loading system

consists of fourteen points through which different fuels are filled in trucks.
The trucks consist of three (generally) chambers in which different fuels are
filled as required. The fuels are pumped through the pipes and the PDM
(positive displacement meter) measures the flow rate. There is also a liquid
controller which removes the liquid vapour (if any). Different fuels like ATF
( Aviation Turbine Fuel ) , MS ( Motor Spirit ) , MTO ( Mineral Turpentine
Oil ) , SKO ( Super Kerosene Oil ) , HSD ( High Speed Oil ) , JBO ( Jute
Batch Oil ) , FO ( Furnace Oil ) , CBFS ( Carbon Black Feed Stock ) and
Microcrystalline Wax are filled in this station .

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Operation: The trucks are weighed and taken to the appropriate point
where first the dip is checked. There is a mercury terminal in the gantry
which display the specification of loading to be done for example the no. of
chambers and capacity etc. on driver’s card punching .The loading operation
is completed on supervisor’s card punching. Then the truck is weighed
again. Subtraction of the tear weight and gross weight gives the net weight.

TANK TRUCK CONTRUCTION:- Tank truck of multi –

compartment type 10-28KL capacity are used for dispatch of product by
road and either be single product or on mixed load.

Fitting of the tanks trucks (for each compartment):-

Manhole with cover-breather valve

Fill valve- Discharge valve

Dip pipe – Moster valve

Vent pipe.

TANK TRUCK MUST MEET THE FOLLOWING

STATIONARY REQUIREMENTS:-

a. Compartment wise calibration chart

b. MVI Registration
c. Explosive licence from CCE.

Tank Wagon Loading ( TWL ) : The petroleum products

(mainly MS, HSD etc.) are also dispatch to different parts of India through
railway wagon.

Operation: Two types of wagon are used in this purpose viz. General
Purpose and BPD (of capacity 64700 lit.) .A primary test is taken for body
leakage. Again the dip is calibrated with the theoretical data. Initially 700 to
1000 lit. Product is given for leak-testing and then the tested wagons are
filled with the products.

Tanker Operation: To import crude and some finished products

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such as MS, HSD, and The purpose of importing the latter two is that
country wide demand of these two products is more than the amount
produced in the refinery. Some other companies such as H.P, B.P also
import crude from abroad.

Types & Capacities of Tanker :

1. G.P(general purpose) series : Small ships (up to 25,000 tons)

2. M.C(medium capacity) series : 25,000 to 45,000 tons
3. L.R(low range) series : Three categories namely L.R-1,L.R-2,L.R-
3(45,000 to 1,20,000 tons)
4. V.L.C.C(very large crude carrier) :1,20,000 to 2,80,000 tons
5. U.L.C.C (ultra large crude carrier) :( 2, 80,000 tons onwards) vessels
of these type do not come to Indian ports.

► per day requirement of Haldia Refinery is 17,000 tons of crude

► as ships move up and downwards due to unloading, and in the time of

tide and ebb tide a special type of joint (chickson) is used in the pipes
between ship & shore. Hinge type joints are used in the coupling.

LPG STORAGE AND FILLING: LPG stands for liquefied

petroleum gas which is a mixture of mainly butane and propane and also
some unsaturated hydrocarbons like propylene and butylenes.

As per Indian standard specifications:-

a. Commercial butane
b. Commercial propane
c. Commercial butane propane mixture(LPG produced at
IOC)

Areas covered with the LPG plant:-

1) Receipt of LPG from crude distillation unit.

2) Storage in Bullets & Horton sphere

3) Filling operation in cylinders & bulk

4) Dispatch in cylinders & by bulk

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 5) Transfer of liquid propane to Deasphalting unit

LPG Bulk Storage :

1) Horton sphere- Four number1500 m³ normal capacity.

2) Bullets-Eight number of 150m³ normal capacity

3) Mounted bullet- 1500 cubic meter.

Bulk Storage:- LPG and Propane are obtained from other units.
Propane is stored in three bullets LPG in the rest five bullets. The LPG
from the bullets is then transferred to Horton sphere.

Horton Sphere:- It consists of a pipe line through which the LPG

enters and leaves when required. The vapour is removed through another
pipe line. When the pressure inside the sphere increases the vapour is
removed by a safety pop to the flare. The LPG in Horton sphere is filled up
to 10.1 m, the height of which is 11 m. The quantity of LPG inside the
sphere is measured by the gauges the top and the temperature of the LPG are
also measured by it.

Bullets :- These gauges are used to check the level of LPG and
Propane inside the bullets. For LPG the bullets are filled up to 210 cm to
220 cm, and for propane it is up to 160 cm, the height of bullets being
260 cm. Water draining and safety pop (for high pressure) are provided
for both the systems. Bulk storage is done by mass flow meter.

Mounted bullets: These types of LPG storage are introduced to

absorb the shock wave if any explosion occurs. Capacity of these tanks is
1500 cubic meter. Bullet tanks are installed inside the concrete layer.

Bulk Loading:- The trucks where LPG is to be filled are taken to the
site of bulk storage. The weight of empty trucks and filled up trucks are
found on a weigh bridge. Their information’s are sent to the control room
which gives the approval for the amount of LPG to be filled in. Two pipes
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are there in the filling site, one through which the product enters the truck
cylinder and the other through which the vapour is taken out to the Horton
sphere and the bullets. The trucks are filled up to the required level and then
dispatched. There are six bulk filling sections and three weigh bridges
having capacities 50MT, 30 MT, 50MT.

Effluent Treatment Plant (ETP):

All the effluents from the refinery are subjected to a purification process
in ETP. Hence, it is one of the important parts of the plant.

EFFLUENT
Raw Effluent EFFLU
from different
process units

Holding
Tank
(TK-104)

WASTE WATER COLLECTION SYSTEM IN HALDIA

Influent Sump
REFINERY:
The various liquid waste water from different units/areas in the refinery have
been segregated into three basics streams .The segregation is based on the
nature of waste water and the treatment require Final
for the removal of the
pollutants and contaminants from the waste water.
The waste water stream and there segregation Clarifier
as follows:
OILY SEWER:
New Aer
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Inner
The system is a broad network of the underground pipes (RCC/CS).The
network covers whole refinery. It collects oil-water mixture from the
refinery and offsite areas and delivers it to the influent sump in Effluent
Treatment Plant. The waste water is brought here by the pipelines and
through tankers. The ETP is in the lower side and all the units are on the
upside, thus the oil flows to this network by gravity.
STROM WATER SEWER:
This system is a open channel network, this covers the whole refinery. The
rain and the storm water are collected inside the dyke of the storage tank and
drained to the network of ETP while draining this water also sometimes get
mix up with the oil which is separated in this unit.
DOMESTIC SEWRAGE:
All the sanitary from toilets and the canteens provided in the refinery
(including the administrative building) are connected to this system. This
connection is made partly by gravity and partly by pumping.

FACTORS CAUSING WATER POLLUTION AT

HALDIA REFINERY AND ITS EFFECTS:
1) OIL :
By the refinery operations, oil from various units ,various tanks ,loading
areas get mixed up with water.
The oil has following effects:
i)It gives an unpleasant odour ,colour to the water.
ii) Cannot be used for various purposes in industry and domestic use.
iii)When discharged in river it reduces algae ,destroy the water plants and
thereby reduces the fish food supply.
iv) Reduces the photosynthesis and the absorption of oxygen from
atmosphere.
v) Affects the water life.
vi) Affects the human life when consumed.
Components in oil causing pollution:
a)Phenols: This are generally the compounds which are produced during the
cracking process in the reformer, visbreaking unit etc. Phenol is present in
very low quantity in cru ed oil also. Although present in very low amount it
causes pollution. This gives unpleasant odour & toxic to human beings when
consumed.
b)Sulphides: The waste water generated at the distillation unit , visbreaker
sour water stripper, kero hydro desulphurisation unit, Hydro finishing unit,
spent caustic generated at caustic wash and merox unit and crude oil tank

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draining sulphides. The effects of the sulphides are: causes bad odour,
corrosive nature, reduces the oxygen in water by rapid consumption leading
to death of water living organism.
c)Suspended solids: These are the sand particles, silt, algae and some iron
compounds. Effects of these suspended solids are: water becomes turbid,
diminishes the sunlight penetration and thus reduces the photosynthesis and
the replenishment of oxygen, deposition at the bottom affects the water
bottom life.
d)Furfural: The furfural is used in used in the FEU as solvent which at
times it finds its way to water sewers. Its effects are: due to presence of this
BOD/COD values will be high, the reduction of phenols, sulphides , oil in
treatment plant becomes poor.

2) BIO-CHEMICAL OXYGEN DEMAND (BOD): It is not a pollutant

itself, but it’s a characteristics of water which in turn depends on other
pollutant. The organism like bacteria and all other things in water utilizes
dissolved oxygen in water for their respiration and multiplication. Thus
there is loss of oxygen in water and this loss is normally made up by
rearetion from atmosphere by using the aerobic bacteria. The water having
pollutants will have high BOD value. Thus BOD is defined as the amount of
oxygen expressed in milligrams per liter required to oxidize components of
waste water biologically.
Effects of high BOD value are:
i)Survival of water bodies is endangered.
ii)The water bodies become anaerobic and give rise to smell.
iii) Water bodies become unfit for beneficial use

3) CHEMICAL OXYGEN DEMAND (COD): The chemical oxygen

demand (COD) test is commonly used to indirectly measure the amount of
organic compounds in water. Most applications of COD determine the
amount of organic pollutants found in surface water (e.g. lakes and rivers),
making COD a useful measure of water quality. It is expressed in milligrams
per liter (mg/L), which indicates the mass of oxygen consumed per liter of
solution. Older references may express the units as parts per million (ppm).
The difference between BOD & COD is only the testing method. In case of
BOD testing, the oxygen requirements are determined by the use of bacteria
& it takes 5 days for testing. However in case COD, the test method utilizes
chemicals and hence can be completed in three hours. All impurities
oxidized in the COD test may not be consumable by bacteria and COD
values are always higher than BOD values.
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EFFLUENT TREATMENT PRINCIPLES: Treatment of the effluent
from the various units of the whole chemical plant is given prodigious
importance. The principle aim of ETP of Haldia Refinery is to obtain water
which is recyclable for numerous purposes in the plant and also to make it
safe for discharging in the outside environment. The effluent consisting of
an emulsion of oil (form various units of plant) and water is treated via a
series of unit operation mainly clarification and continuous settling.
Effective chemical and biological treatments are also done to render
flocculation, lowering BOD & COD of the water. These treatments have
been described in the upcoming section.
The Haldia Refinery of IOCL has two sets of ETP: one which has been
under operation for many years since its establishment while the other is a
modernized plant, with employment of the latest methods of separation of
oil water emulsion. The underlying principle of operation being the same,
the two Effluent Treatment Plants differs in few unit operations and the
types of equipments which have been installed.
The steps in waste water treatment are as follows:
a) Physical Treatment.
b) Chemical Treatment.
c) Biological Treatment.

PROCESS DESCRIPTION:
a) Physical Treatment: Water waste of refinery contains coarse suspended
and floating solids, oils etc. settle able pollutants. These need to be removed
before the waste water is subjected to chemical and biological treatment. By
physical treatment the pollutants are removed. Rakes and screens, grinder,
grid chamber, grease traps, flocculation, sedimentation, sludge pumping etc.
are common physical treatment operations. In Haldia Refinery, bar screen,
wire mesh, and API Separator (in case of modernized installation Tilted
Plate interceptor) are used for purpose of physical treatment. Effluent is first
admitted through bar screen and then wire mesh where debris, rags etc. are
removed & then sent through grid chamber to settle out suspended solids.
The purpose of these two equipments is to protect the downstream
mechanical equipment and avoid deposition in sumps and channels. The
waste water with free oil and sludge is then routed through the API
separators and then the primary sedimentation equipment. Here the velocity
of the influent is slowed down considerably, at such a low velocity, the
suspended particles of higher density are made to settle down and the oil of

95
low density floats. In API around 50% to 60% of suspended solids are
removed and 20% to 40% of the BOD at 20oC is achieved.

b) Chemical Treatment: Chemical treatment followed by physical

treatment reduces colloidal solids, inorganic chemicals, some portion of
organic chemicals and the remaining suspending solids of the effluent.
Important unit operations and processes which are used for this purpose are:
i) Chemical coagulation, flocculation and sedimentation
ii) Filtration
iii) Ion exchange
iv) Reverse osmosis
v) Carbon adsorption
In Haldia refinery method number (i) along with oxidation of chemical both
organic and inorganic (especially sulphide and phenolic compound) by
chlorine is followed. Coagulation is the process in which chemical which is
termed as coagulant are added to an aqueous system to create rapidly settling
aggregate out of present. Flocculation is the second stage in the formation of
this aggregate which is achieved by gentle and prolonged mixing. Over here
coagulation occurs in pre-aeration chamber. [the coagulant] solution
and lime solution are added in pre-aeration chamber. Positively charged iron
ions neutralize the negative charges of emulsified oil and hence releases the
oil from water. These iron ions are hydrolyzed by hydroxides [like
] to form flocs. Dissolved in the effluent oxidizes the
to flocs which settles at faster rate than . For highest
efficiency a rapid and intimate mixing of / flocs with
effluent is necessary before flocculation process begins, which is done in
flash mixer chamber where a motor driven stirrer is rotating continuously.
Flocs so formed are too light to settle under gravity, thus from the flash
mixer chamber the effluent goes to clariflocculator where slow stirring is
done by two continuously rotating motor driven stirrer thus enabling
flocculation i.e. agglomeration of small flocs. Entrainment and absorption of
suspended particles (such as free oils, FeS etc.) occurs on the large surface
area of the agglomerated / flocs which settle down at the
clarifier zone of the clariflocculator.

c) Biological Treatment: After physical and chemical treatment waste

water is to biological treatment under aerobic condition (i.e. a condition
denoting an excess of free dissolved oxygen (o2) in biological system) for
further reduction of organic pollutant. The principles involved is to utilize

96
naturally occurring bacteria to eat away or oxidize organic impurities there
by reducing the concentration of pollutants. These bacteria simultaneously
get biodegraded. The excess of bacteria is removed from the system
periodically. The basic biochemical reaction for the stabilization of organic
impurities under aerobic condition by micro-organisms in waste water is as
follows:
Organic impurities + microbes + A more microbes +CO2 +H2O +waste

The common systems for biological treatment are Trickling filter and
Activated sludge tank also called as aeration tank or bio-reactor. Both
are used in Haldia refinery.
In case of trickling filter (bio filter) system, waste water is sprayed on bed
of stones. The aeration is form on the bottom of the stones upwards, due to
temperature difference of water and the ambient air, bacteria grows on the
stone surface as a film which eats away organic impurities. These bacteria
decay and wash out periodically. Fresh bacteria grow again on the stones.
In case of activated sludge tank, the bacteria are continuously mixed with
waste water and aerated by motor operated aerators. Here also bacteria eat
away impurities. The bacteria water (mixed liquor) is then sent to clarifier
from aeration tank where bacteria mass separated from water. The bacteria
mass is recycled back to aeration tank to maintain required level of bacteria
mass in aeration tank. The balance of bacteria is sent to biological sludge
lagoons ( this operation is done periodically ) for disposal. The water from
clarifier goes to treated water pond, ready for disposal to river.
The nutrient used in Bio-reactor is Urea.

PRODUCT DESPATCH

Generally bulk oils are bought and sold on the basis of volume
corrected to 15oC. Only LPG and bitumen are bought and sold on the
basis of weight.

It is done by four different ways:

1. Road (15%).
2. Rail (23%).
3. Barges & tankers (22%).
4. Pipelines (40%).

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There are two main pipelines present

1. HMR (Haldia – Mourigram – Rajbandh)

2. HB (Haldia – Barauni)

CONCLUSION

Industrial training is very much important for chemical engineering point

of view. Here all units very much important and every unit have an
important objective.

Form CDU, we are knowing how to occur physical separation and

deferent products and various process equipment and unit operation

Form VDU, we know how to occur physical separation and deferent

products and various process equipment and unit operation. Here we are
seeing how to occur vacuum.

From DHDS, KHDS & SRU, we get wide knowledge of sulfur recovery
which is much important for environmental aspect and we know how to
remove sulfur and various process equipment and unit operation

Today LPG &Gasoline are more important for automobile and

domestic purpose, but form CDU, we get less amount LPG & Gasoline than
our requirement. So, FCCU give LPG & Gasoline which is more important
for our requirement.

Haldia refinery take important role for Lube oil production and
separation of aromatics wax and asphalt from lube oil is very much
important.

Above all from the point of view of a chemical engineering, it is very much
important. Actually this plant is the application of mass transfer, heat
transfer, fluid mechanics and thermodynamics which is close relation and
heart of chemical engineering.

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