VOCATIONAL TRAINING REPORT

INDIAN OIL CORPORATION LTD

Training Period – May 14,2018 To June 28,2018

Submitted by:
BHENSANIYA VIVEK RAMNIKLAL
AAKRITI
KISHNA RAM CHOUDHARY

Submitted to :
Mr.VIJENDER KUMAR, Officer (L and D) Training &
Development Department IOCL

In partial fulfilment of requirements for the degree of

BACHELOR OF TECHNOLOGY
CHEMICAL DEPARTMENT
PREFACE

Industrial training plays a vital role in the progress of

future engineers. Not only does it provide insights about
the future concerned, it also bridges the gap between
theory and practical knowledge. We are fortunate that we
were provided with an opportunity of undergoing an
industrial training at INDIAN OIL CORPORATION LTD.
(GUJARAT REFINERY). The experience gained during this
short period was fascinating to say the least. It was a
tremendous feeling to observe the operation of different
units and processes. It was overwhelming for us to notice
how such a huge refinery is being monitored and
operated with proper coordination to achieve desired
results. During our training, we realised that in order to
be a successful chemical engineer, one needs to put
his/her concepts into action. Thus, we hope that this
training serves as a stepping stone for us in future and
help us carve a niche for ourselves. in this field.
ACKNOWLEDGEMENT
My indebtedness and gratitude to the many individuals
who have helped to shape this report in its present form
cannot be adequately conveyed in just a few sentences.
Yet we must record our immense gratitude to those who
helped us undergo this valuable learning at IOCL.

We are highly obliged to Training and Development

Department for providing us this opportunity to learn at
IOCL. We have further more to thank the officers of
production for sharing their knowledge about the plant
and production process. It is really a great opportunity
for us by which we have gained knowledge which is
usually hard to find in textbooks. My special thanks to –

Mr. VIJENDER KUMAR, OFFICER (L & D).

Mr. P.K. VERMA, SPNM(AU-I)
Mr. PIYUSH DIWAKER, SPNM (DCU)
Mr. K.N. KOTECHA, SPNM(SRU)
Mr. D.B. VYAS, SPNM(ARU-III)
Mr. PANKJA PATIL, CPNM(FCU)
INDEX
TOPIC PAGE.NO.
1) ABOUT INDIAN OIL CORPORATION 4
LTD
2) INDIAN OIL (ENERGY OF INDIA) 5
3) VISION 6
4) REFINERIES 8
5) Gujarat Refinery 12
6) IOCL Pipelines 17
7) Basic Outline of the Crude Refining 18
process done at Gujarat Refinery
8) MANUFACTURING OF LINEAR 25
ALKYL BENZENE
➢
INTRODUCTION AND
HISTOR
➢
PREFACTIONATION SECTION
➢
UNIONFINING SECTION
➢
MOLECULAR EXTRACTION
(MOLEX)
➢
PACOL UNIT:
➢
PACOLATE ENHANCEMENT
PROCESS
➢
DETAL SECTION
➢
EQUIPMENTS
9) FLUIDISED CATALYTIC CRACKING 72
UNIT
10) MS QUALITY UPGRADATION 77
11) DELAYED COKER UNIT 80
12) UTILITY 83
ABOUT INDIAN OIL CORPORATION
LTD.
Indian Oil Corporation (Indian Oil) is India's largest
commercial enterprise, with a sales turnover of Rs.
4,38,710crore (USD 65,391 million) and profits of Rs.
19,106 crore (USD 2,848 million) for the year 2016-17.
The improvement in operational and financial
performance for FY 2016-17 reflected in the market
capitalization of the Company, which grew two-fold, from
Rs. 95,564 crore as on 31st March 2016 to Rs. 1,87,948
crore as on 31st March 2017. In view of its rising share
price and market capitalization, Indian Oil was included in
the Nifty50 index (NSE benchmark index of 50 best
performing corporates). Indian Oil is ranked 161st among
the world's largest corporates (and first among Indian
enterprises) in the prestigious Fortune ‘Global 500’ listing
for the year 2016.

As India's flagship national oil company, with a 33,000-

strong work-force currently, IndianOil has been meeting
India’s energy demands for over half a century. With a
corporate vision to be 'The Energy of India' and to
become “A globally admired company”, IndianOil's
business interests straddle the entire hydrocarbon value-
chain – from refining, pipeline transportation and
marketing of petroleum products to exploration &
production of crude oil & gas, marketing of natural gas
and petrochemicals, besides forays into alternative
energy and globalization of downstream operations.
Having set up subsidiaries in Sri Lanka, Mauritius and the
UAE, the Corporation is simultaneously scouting for new
business opportunities in the energy markets of Asia and
Africa. It has also formed about 20 joint ventures with
reputed business partners from India and abroad to
pursue diverse business interests.
INDIAN OIL (ENERGY OF INDIA)
Indian Oil accounts for nearly half of India's petroleum
products market share, 35% national refining capacity
(together with its subsidiary Chennai Petroleum
Corporation Ltd., or CPCL), and 71% downstream sector
pipelines through capacity. The Indian Oil Group owns
and operates 11 of India's 23 refineries with a combined
refining capacity of 80.7 MMTPA (million metric tonnes
per annum).

The Corporation's cross-country pipelines network, for

transportation of crude oil to refineries and finished
products to high-demand centers, spans about 12,848
km. With a throughput capacity of 93.7 MMTPA for crude
oil and petroleum products and 9.5 MMSCMD for gas, this
network meets the vital energy needs of the consumers
in an efficient, economical and environment-friendly
manner.

The Corporation has a portfolio of leading energy brands

that includes Indane LPG cooking gas, SERVO lubricants,
XTRAPREMIUM petrol, XTRAMILE diesel, PROPEL
petrochemicals, etc. Besides Indian Oil, both SERVO and
Indane have earned the coveted Super brand status.
➢
COUNTRYWIDE REACH:

Indian Oil's network of over 46,000 customer touch-

points reaches petroleum products to every nook and
corner of the country. These include more than 26,000
petrol & diesel stations, including 6,565 KisanSeva
Kendra outlets (KSKs) in the rural markets. Over 10,000
fuel stations across the country are now fully automated.

The Corporation has a 65% share of the bulk consumer

business, and almost 6,500 dedicated pumps are in
operation for the convenience of large-volume consumers
like the defence services, railways and state transport
undertakings, ensuring products and inventory at their
doorstep. They are backed for supplies by 129 bulk
storage terminals and depots, 101 aviation fuel stations
and 91 LPG bottling plants.
VISION
Indian Oil’s ‘Vision with Values’ encompasses the
Corporation’s new aspirations
– to broaden its horizons, to expand across new vistas,
and to infuse new-age dynamism among its employees.

Adopted in the company’s Golden Jubilee year (2009), as

a ‘shared vision’ of Indian Oil People and other
stakeholders, it is a matrix of six cornerstones that would
together facilitate the Corporation’s endeavours to be
‘The Energy of India’ and to become ‘A globally admired
company.’

More importantly, the Vision is infused with the core

values of Care, Innovation, Passion and Trust, which
embody the collective conscience of the company and its
people, and have helped it to grow and achieve new
heights of success year after year.
Gujarat Refinery

The Gujarat Refinery is an oil refinery located at Koyali

(Near Vadodara) in Gujarat, Western India. It is the
Second largest refinery owned by Indian Oil Corporation
after Panipat Refinery. The refinery is currently under
projected expansion to 18 MMTPA.
➢
HISTORY:

Following the conclusion of the Indo-Soviet Treaty of

Friendship and Cooperation in February 1961, a site for
the establishment of a 2 million metric ton per annum
(mmtpa) oil refinery was selected on 17 April 1961.
Soviet and Indian engineers signed a contract in October
1961 for the preparation of the project. Prime Minister
Jawaharlal Nehru laid the foundation stone of the refinery
on 10 May 1963.

The refinery was commissioned with Soviet assistance at

a cost of Rs.26 crores began production in October 1965.
The first crude distillation unit with a capacity of 1 mmtpa
was commissioned for trial production on 11 October
1965 and achieved its rated capacity on 6 December
1965. Throughput reached 20% beyond its designed
capacity in January 1966.

President Sarvepalli Radhakrishnan dedicated the refinery

to the nation with the commissioning of second crude
distillation unit and catalytic reforming unit on 18 October
1966.

The third 1 mmtpa distillation unit was commissioned in

September 1967 to process Ankleshwar and North
Gujarat crudes. In December 1968, Udex plant was
commissioned for production of benzene and toluene
using feedstock from CRU. By 1974-75 with in-house
modifications, the capacity of the refinery increased by
40% to a level of 4.2 MMTPA. To process imported crude
the refinery was expanded during 1978-79 by adding
another 3 MMTPA crude distillation unit along with
downstream processing units including vacuum
distillation, visbreaker and bitumen blowing units. By
1980-81 this unit started processing Bombay High crude
in addition to imported crudes. It was the first time that
Indian engineers independently handled a project of that
scale.

To recover products from the residue, secondary

processing facilities consisting of fluidized catalytic
cracking unit of 1 MMTPA capacity along with a feed
preparation unit of 1 MMTPA capacities, were
commissioned in December 1982. The refinery set up
pilot distillation facilities for the production of n-Heptane
and light aluminum rolling oils. To enable absorption of
increased indigenous crudes the refinery's capacity was
further increased to 9.5 MMTPA.

In 1993-1994, Gujarat commissioned the country's first

hydrocracker unit of 1.2 MMTPA along with feed
preparation unit-2 and hydrogen generation unit-1 (GHC
Complex), for conversion of heavier ends of crude oil to
high value superior products.

India's first diesel hydro-desulfurisation unit to reduce

sulfur content in diesel was commissioned in June 1999.
An methyl tertiary butyl ether unit was commissioned in
September 1999 to eliminate lead from motor fuels. The
facility conceptualized and commissioned South Asia's
largest centralized effluent treatment plant by
dismantling the four old ETP's[expand acronym] in June
1999. By September 1999 with the commissioning of an
atmospheric distillation unit, Gujarat Refinery further
augmented its capacity to 13.7 MMTPA making it the
largest public sector undertaking refinery of the country.
A project for production of linear alkyl benzene from
kerosene streams was implemented in August 2004. It is
the largest grassroots single train Kerosene-to-LAB unit
in the world, with an installed capacity of 1.2 mmtpa. To
meet future fuel quality requirements, MS quality
improvement facilities were commissioned in
2006.Residue Upgradation Project undertaken by the
Gujarat Refinery was completed by 2011 which increased
the high sulfur processing capacity of Gujarat refinery,
improved the distillate yield as well produce BS III & IV
quality of MS and HSD. The Residue upgradation project
came in two parts namely, the south block which
consisted of HGU-III, SRU-III, DHDT and ISOM units and
the north block consisted of VGO-HDT and DCU units. To
support the new units a new Co-Generation Plant (CGP)
and Heat Recovery Steam Generation (HRSG) were also
commissioned.
 ➢
DESCRIPTION:

The refinery's facilities include five atmospheric crude

distillation units. The major secondary units include
Catalytic Reforming Unit (CRU), Fluidized Catalytic
Cracking Unit (FCCU)and the first hydrocracking unit of
the country. Through a pipeline to Ahmedabad and a
pipeline connecting to the BKPpipeline and also by rail
and truck, the refinery primarily serves the demand for
petroleum products in western and northern India.

When commissioned, the refinery had an installed

capacity of 2 mmtpa and was designed to process crude
from Ankleshwar, Kalol and Nawagam oilfields of ONGC
in Gujarat. The refinery was modified to handle imported
and Bombay High crude. The refinery also produces a
wide range of specialty products such as benzene,
toluene, MTO, food grade hexane, solvents and
LABFS[expand acronym].

The Gujarat Refinery is the first refinery in India to have

completed the diesel hydrodesulfurization project in June
1999, when the refinery started production of HSD with
low sulfur content of 0.25% wt (max).
IOCL Pipelines
IOCL operates a network of about 12848 km long crude
oil, petroleum product and gas pipelines.

Map for IOCL Pipelines throughout the country.

Basic Outline
Report
1. Atmospheric distillation unit
1.1Introdution to distillation
Distillation is a process by which two or more
substances with different boiling points can be
separated from each other. Distillation because of
difference in relative volatility. Relative volatility is
the measure of the difference in volatility between
two components, and hence their boiling points.

Relative volatility of component “a” w.r.t “b” is

Aij = (yi/xi)/(yj/xj)

1.2 Design Information

a) Introduction
Atmospheric Distillation Unit was designed to
process 1.0 MMTPA of Ankleshwar Crude. It was
commissioned on 25.09.1966. the unit was
revamped to process North Gujarat Crude as well
as Bombay High Crude. The unit was revamped to
increase the capacity to 2.2 MMTPA in April 1988.

Atmospheric unit consists of Electrostatic Desalter,

preflash column K-1, Main fractionating column
K-2, Naptha stabilizer K-5, Reformate splitter K-7
with feed from MSQ, Naptha splitter K-8 & PGH
section K-9.
b) Functions of the Plant.
After revamp, unit can process Ankleshwer, north
Gujarat, Bombay high crude in any proportion.

Various products from this unit are:

✓ LPG
✓ Light reformate
✓ PGH
✓ ATF
✓ SK or LABS
✓ IBP-60
✓ BS-2
✓ LSHS

c) Crude Distillation
i. CRUDE STORAGE AND SETTLING
Ankleshwer, North Gujarat & Bombay High crude
oils are received through their respective
pipelines and then stored in their respective
storage tanks.

Adequate settling time of 12 hrs. has to be

allowed after receipt of
water/sludge. The water is
thoroughly drained before feeding to the unit.
The sludge from the tank is drained to pit.
ii. CRUDE BOOSTER PUMP
5 crude pumps are provided for supplying crude
to the GR unit.
Out of the 5 pumps, 2 pumps are in NG crude
service, and 1 each in
ANK and BH service.

iii. CRUDE PREHEAT CIRCUIT BEFORE DESALTER

Crude through the feed line reaches the crude

feed pump P1, P2, P206. With the help of fuel
pump, crude is pumped to series of heat
exchanger to recover the heat from run down
products. Desalter pressure is maintained 10-12
Kg/cm2 by 2PC 2101 installed at discharge of
crude pumps. Crude passes through shell side of
ATF heat exchanger E- 201. A provision is given
to add DM water upstream of E-201 in case of
requirement.

iv. DESALTER
Crude enters for removal of salt and water at
bottom section of the desalter through an inlet
distributor. Crude is initially mixed with
adequate amount of DM water (3%) with the
help of mixing valve. Recommended pressure
drop across mixing valve is 1.2 to 1.6 Kg/cm2.
 Adequate settling time is allowed to break the oil
water emulsion and salt water to settle down in
desalter. The desalted crude is withdrawn with
the help of outlet crude collector mounted on
the top most part inside the desalter. The
separated effluent water with dissolved salts is
drawn through interface level controller and
exchange heat with DM water. Effluent water is
then drained through a flash drum. Interface
level is maintained around 50%. The exact
interface level for efficient desalting will depend
upon the salt content and appearance of effluent
water.

v. CRUDE PERHEAT CIRCUIT AFTER DESALTER

Crude ex desalter passes through tube side of
HSD CR exchanger T1 or/and then divides in two
parts and passes through E-13 A/B and E-11
A/B via 2FI-2202 & 2FI-2201 RCO exchangers
or/and then divides in two parts and enters
parallely in E-10A and E-10B HSD exchangers
via 2FI-2203 & 2FI-2204 crude flow is controlled
by 2FC-2210 installed at the outlet of desalter in
order to maintain K-1 level. Crude ex E10A/B is
divided into two parts and passes through tube
side of RCO heat exchanger (i) T-3A, T-4I, T-4G
and (ii) T- 3B, T-2A, T4H through flow indicator
2FI-2205 and 2FI-2206 respectively. Crude flow
 through heat exchanger is adjusted to optimize
heat recovery from RCO.

vi. CRUDE PRETOPPING COLUMN K-1

The preheated crude enters the pre-topping
column K-1 above tray No.9. This column is
meant for removal of lighter ends from the
crude and has 28 trays. (1 to 9 is double pass
valve trays, 10 to 16 are single pass valve trays
and 17 to 28 are double pass channel trays).
Column K-1 has been provided with 50%
capacity 3 Nos. of safety valves PSV-3301 A, B,
C set at 3.5 Kg/cm2 (g) pressure releasing
excess pressure to flare.

The column is operated at 3.0 Kg/cm2 (g) and

245 Deg.C bottom temp. Light naphtha boiling
up to about 130 Deg.C is recovered as overhead
product from this column, which also contains
lighter hydrocarbons like gas and LPG. The
overhead vapors are condensed and cooled in
the condensers T-11 A/B/C working in parallel
and product is received in the reflux drum E-1.
Corrosion inhibitor 'Ahuralan' is injected in
overhead vapor line to avoid corrosion in
condensers & reflux drum and ammonia solution
is injected to control PH of E1 boot water to 6 to
6.5.
 vii. FURNACE
➢ FURNACE F-1
Furnace F-1 has two separate radiation K-1
side and K-2 side and common convection
zone. K-1 side cell supplies re-boil heat to
column K-1/K-2 and K-2 side cells and
convection section provides heat for
vaporization of distillates in K-2 feed. To
improve furnace efficiency F-1 has been
provided with air pre-heaters (APH), FD fan
and ID fan.

➢ F-1 HEATER, K-1 SIDE

Liquid from K-1 bottom pump P-4/4A enters
F-1 (K-1 side), having two passes, through
2FC-2356, and 2FC-2357 at around 250 Deg.C
to 265 Deg.C.

➢ F-1 HEATER K-2 SIDE

Other part of liquid from K-1 bottom pump P-
4/4A enters common convection section
having two passes through flow controller
2FC-2358 and 2FC-2359 at around 265 Deg.C.
Pre-topped crude after getting heated up in
common convection section, enters F-1 (K-2
side) radiation zone. Temperature indicators
 2TI-2373 and 2TI-2374 and pressure gauges
on cross over between convection zone and
radiation zone are provided on pass-1 and 2
respectively. Crude is heated to the desired
temperature (around 350 Deg.C) to get 3 to
4% over flash in column K-2.

➢ AIR PREHEATER CIRCUIT

The Air Pre-heater circuit improves the
efficiency of the furnace F-1 from 88% to 90%
by exchanging heat between the hot flue
gases leaving furnace and combustion air. The
APH system consists of two common
recuperative type air pre-heater, ID fan and
FD fan. Flue gases from K-1 side and K-2 side.
Combustion is sucked from atmosphere by FD
fan.

viii. COLUMN K-2 FEED ENTRY AND OVERHEAD

SYSTEM
The partially reduced crude heated to 350 Deg.C
enters the main fractionating column K-2 above
the 6th tray. Column K-2 have 5 Nos. of safety
valves PSV-3401, A, B, C, D,E set at 1.6 Kg/cm2
are provided on the vapor lines to condenser
outlet out of five safety valve, three shall remain
on line. These PSVs releases excess pressure to
newly installed LP flare system.
 The column K-2 is operated at 0.8 KG/cm2 (g)
pressure and 1400 C top temperature. Column
K-2 pressure is controlled with the help of split
range controller 2PC-2401 acting on the gas line
of its reflux accumulator E-2. This pressure
controller admits gas into E-2 or releases gas
from E-2 to flare depending on whether the
column K-2 pressure is lower or higher than
desired.

d) CHEMICAL INJECTION SYSTEM

Chemical injection system is provided in the unit to
achieve the following:
1. To facilitate emulsification in Desalter, emulsifier
is added.
2. To protect K-1, K-2 and K-5 overhead systems
against corrosion, ammonia water, Ahuralan and
caustic solution is added.

✓ DEMULSIFIER
A emulsifying agent is injected into the crude
oil at the crude pumps common suction header
in the unit at the rate of 6ppm on crude T’put
and at the rate of 10ppm on T’put while
processing slop. Demulsifier helps in faster
emulsification inside the Desalter, thereby
helping in faster removal of water injected for
dissolving salt. Emulsifier is injected with the
help of pump P-222 A/B which takes suction
from emulsifier tank. A rota-meter is provided
for checking pumping rate. Injection rate of
 demulsifier is adjusted by varying the pump
stroke.

✓ CAUSTIC INJECTION
Calcium and Magnesium Chloride present in
crude hydrolyses on heating and releases HCL
that attacks the overhead system. Some of
these calcium and magnesium chloride are
removed in the Desalter. To neutralize the
chlorides escaping from Desalter, caustic
solution is added into crude. In presence of
caustic they get converted into harmless NaCl.
The caustic dosing is done at a fixed rate of
40ppm on N/G crude throughput and is
injected in crude outlet line from Desalter.

✓ AMMONIA SOLUTION INJECTION

Ammonia is injected into vaporlines of K-1/K-2

to:

a . Neutralize residual hydrochloric acid by

converting it into NH4Cl
b. Maintain pH of E-1/E-2 water in the range of
6 to 6.5, because effectiveness of corrosion
inhibitor is more in this range of pH.
✓ AHURALAN ESK-50 INJECTION
It is an organic chemical, which acts as a
corrosion inhibitor by forming a continuously
renewable monomolecular layer on the metal
surface, thereby preventing direct contact of
the metal surface with the corrosive elements
present in the system. The dosing was done in
the top section of K-1, K-2, K-5 & K-7
separately, at the rate of 5ppm of production
of overhead material in the respective
columns.
2. DELAYED COKING UNIT

A delayed coker is a type of coker whose process consists

of heating a residual oil feed to its thermal cracking
temperature in a furnace with multiple parallel passes.
This cracks the heavy, long chain hydrocarbon molecules
of the residual oil into coker gas oil and petroleum coke.
Delayed coking is one of the unit processes used in
many oil refineries. The delayed coking unit consists of 4
drums. However, larger units have tandem pairs of
drums, some with as many as 8 drums, each of which
may have diameters of up to 10 meters and overall
heights of up to 43 meters.
The yield of coke from the delayed coking process ranges
from about 18 to 30 percent by weight of the feedstock
residual oil, depending on the composition of the
feedstock and the operating variables. The capacity
of DCU (Gujarat refinery) is 3.7MMTPA.
Residual oil from the vacuum distillation unit (sometimes
including high-boiling oils from other sources within the
refinery) is pumped into the bottom of the distillation
column called the main fractionator. From there, it is
pumped, along with some injected steam, into the fuel-
fired furnace and heated to its thermal cracking
temperature of about 480 °C. Thermal cracking begins in
the pipe between the furnace and the first coke drums,
and finishes in the coke drum that is on-stream. The
injected steam helps to minimize the deposition of coke
within the furnace tubes.
Pumping the incoming residual oil into the bottom of the
main fractionator, rather than directly into the furnace,
preheats the residual oil by having it contact the hot
vapors in the bottom of the fractionator. At the same
time, some of the hot vapors condense into a high-boiling
liquid which recycles back into the furnace along with the
hot residual oil.
As cracking takes place in the drum, gas oil and lighter
components are generated in vapor phase and separate
from the liquid and solids. The drum effluent is vapor
except for any liquid or solids entrainment, and is
directed to main fractionator where it is separated into
the desired boiling point fractions.
The solid coke is deposited and remains in the coke drum
in a porous structure that allows flow through the pores.
Depending upon the overall coke drum cycle being used,
a coke drum may fill in 16 to 24 hours.
After the first drum is full of the solidified coke, the hot
mixture from the furnace is switched to the second drum.
While the second drum is filling, the fulled first drum is
steamed out to reduce the hydrocarbon content of the
petroleum coke, and then quenched with water to cool it.
The top and bottom heads of the full coke drum are
removed, and the solid petroleum coke is then cut from
the coke drum with a high-pressure water nozzle, where
it falls into a pit, pad, or sluiceway for reclamation to
storage.
Composition of coke
The table below illustrates the wide range of
compositions for raw petroleum coke (referred to
as green coke) produced in a delayed coker and the
corresponding compositions after the green coke has
been calcined at 2375 °F (1302 °C):

Composition Of Coke From A Delayed Coker

Green coke Coke calcined

Component
as produced at 2375 °F

Fixed carbon, wt % 80 – 95 98.0 − 99.5

Hydrogen, wt % 3.0 − 4.5 0.1

Nitrogen, wt % 0.1 − 0.5

Sulfur, wt % 0.2 − 6.0

Volatile matter, wt % 5 – 15 0.2 − 0.8

Moisture, wt % 0.5 – 10 0.1

Ash, wt % 0.1 − 1.0 0.02 − 0.7

Density, g/cm3 1.2 − 1.6 1.9 − 2.1

Metals, ppm weight:

Aluminum 15 – 100 15 − 100

Boron 0.1 – 15 0.1 − 15

Calcium 25 – 500 25 − 500

Chromium 5 – 50 5 − 50

Cobalt 10 – 60 10 − 60

Iron 50 − 5000 50 − 5000

Manganese 2 – 100 2 − 100

Magnesium 10 – 250 10 − 250

Molybdenum 10 – 20 10 − 20

Nickel 10 – 500 10 − 500

Potassium 20 – 50 20 – 50

Silicon 50 – 600 50 – 600

Sodium 40 – 70 40 – 70
Uses of petroleum coke
The product coke from a delayed coker has many
commercial uses and applications. The largest use is as a
fuel.
➢ The uses for green coke are:

• As fuel for space heaters, large industrial steam

generators, fluidized bed combustions, Integrated
Gasification Combined Cycle (IGCC) units
and cement kilns
• In silicon carbide foundries
• For producing blast furnace coke
➢ The uses for calcined coke are:

• As anodes in the production of aluminum

• In the production of titanium dioxide
• As a carbon raiser in cast iron and steel making
• Producing graphite electrodes and other graphite
products such as graphite brushes used in electrical
equipment
• In carbon structural materials
Other processes for producing
petroleum coke
There are other petroleum refining processes for
producing petroleum coke, namely the Fluid Coking and
Flexicoking processes both of which were developed and
are licensed by ExxonMobil Research and Engineering.
The first commercial unit went into operation in 1955.
Forty-three years later, as of 1998, there were 18 of
these units operating worldwide of which 6 were in the
United States.
There are other similar coking processes, but they do not
produce petroleum coke. For example, the Lurgi-VZK
Flash Coker which produces coke by the pyrolysis of
biomass.

➢ Types of petroleum coke

There are different types of coke depending upon
different properties: -
1. Depending upon structure
a. Sponge coke
b. Needle coke
c. Shot coke
2. Depending upon end use of coke
a. Fuel grade coke
b. Anode grade coke
c. Needle grade coke
 • SPONGE COKE: - Depending upon strict properties,
sponge coke can be used in its raw form for fuel and
it can also be used for calcination in aluminium
industry.
• NEEDLE COKE: - This type of coke has needle like
structure and is produced from feedstock having high
aromaticity. It contains low nitrogen and sulphur
content and low coefficient of thermal expansion.
• SHOT COKE: - It is the undesired type of coke and is
produced from high asphaltenes content feed. Its
size range varies from golf ball to football.
• FUEL GRADE COKE: - It is used in the production of
cement and for steam and electricity in power plant.
• ANODE GRADE COKE: - This type of coke has low
sulphur content usually calcined and is used in the
production of electrodes for aluminium furnace.
• NEEDLE GRADE COKE: - It is used in the
manufacturing of graphite electrodes which are used
in electric arc furnaces in steel industry.

✓ YIELDS AND QUALITY OF PRODUCTS ARE DIRECTLY

RELATED TO THREE PROCESS VARIABLES: -

1. Temperature
2. Pressure
3. Recycle ratio (Throughout ratio)
3. SULPHUR RECOVERY UNIT
SRU is having two trains each of 300 MTPD capacity with
common TGTU and storage and loading facilities. The
amine acid gas feed from the ARU enters each SRU train
at 45 degree Celsius (0.7 kg/cm2g) where it mixes with
the 55 degree Celsius recycle gas from TGU. The mixed
gas enters acid gas KOD. The SWS gas feed from the
sour water stripper unit is introduced via the knock-out-
drum. Sour water, separated in the knock out drums, is
intermittently collected in the sour water drain sump.
The gas is divided into two streams. One portion enters
the reaction furnace through the burner, where it is
partially oxidized along with all of SWS acid gas at 1300-
1470℃ to ensure total destruction of ammonia.
The remainder of amine acid gas is directed to the
second zone of the reaction furnace, the reaction
chamber.

The combustion air is supplied by two of three Claus air

blowers. The flow of combustion air to the SRU is
controlled to produce the desired amount of SO2 in the
reaction furnace by rationing by air flow to the flows of
the feed streams.
All the combustion air is supplied to the combustion
chamber (zone 1) of the reaction furnace with a portion
of the amine acid gas and all of the SWS acid gas.
Under no circumstances should the temperature in the
combustion chamber exceed 1540 degree Celsius or be
allowed to fall below 1300 degree Celsius. The hot gases
flow from reaction chamber to the waste heat boilers.
The gas is cooled in two pass process coolers, thereby
generating HP steam. The steam is produced at
33kg/cm2g in steam generator, cooling the process gas
to 649 degree Celsius in first pass and to 316 degree
Celsius in second pass. Then the process gas is
introduced into first sulphur condenser in which it is
cooled to 177 degree Celsius there by generating LP
steam at 4.4 kg/cm2g , the sulphur vapour is condensed
and the liquid sulphur is separated from the gas.
Upstream of the first reactor, the process stream from
the west heat boiler is heated to 227 degree Celsius by
the steam reheater to obtain the optimum temperature
for the catalytic conversion.

Because the conversion reaction is exothermic, the gas

exits at 282 degree Celsius. The effluent gas from the
first reactor passes through the second sulphur
condenser.

The second reheater and second converter are provided

and function is much the same way as the first reheater
and the first converter.
The gas enters the final condenser, where sulphur is
again condensed, separated, and sent to seal pot and
then to sulphur pit. The Claus tail gas is cooled to 132
degree Celsius by preheating the boiler feed water to 121
degree Celsius before entering the shell side of the final
condenser.
 ➢ REACTION CHEMISTRY
✓ Clause section reactions: -
2 H2S +3 O2 → 2 SO2 + 2 H2O
4 H2S +2 SO2 → 3 S2 + 4 H2O
2NH3 + 3/2 O2 3H2O + N2
The sulphur is formed as a vapor, and other forms of
elemental sulphur are formed in the gas. The
predominant reactions producing the other forms are:

3S2 S6 + heat
4S2 S8 + heat
Some side reactions are described by the equations
below:-
CH4 + 2O2 CO2 + 2H2O
CO2 + H2S COS +H2O
COS + H2S CS2 +H2O
2H2S +heat 2H2 + S2
COS + H2O H2S + CO2
4.FLUID CATALYTIC CRACKING
UNIT
In 1982 Gujarat Refinery FCC Unit was commissioned
with a capacity of 1 MMTPA. The requirement of LPG and
Gasoline has been increased and to meet that
requirement this unit has been revamped to 1.5 MMTPA
in 1999-2000.
➢ This UOP designed Fluidized Catalytic Cracking Unit
consists of three sections: -

a. Catalyst Section
b. Fractionation Section
c. Gas Concentration Section

➢ CATALYST SECTION: - The Catalyst Section consists

of the Reactor and Regenerator, which, together with
the Stand Pipes and Riser, form the “Catalyst
Circulation System”. The catalyst circulates up the
Riser to the Reactor, down through the Stripper to
the Regenerator across the Regenerator Standpipe,
and back to the Riser. Fresh feed and recycle
streams, known as Combined Feed, are vaporized
and heated to the reactor temperature by the hot
catalyst. This mixture of oil vapour and catalyst
travels up the Riser into the Reactor. The gas oil
commences to crack immediately when it contacts
the hot catalyst in the Riser and continues until the
oil vapours are disengaged from the catalyst in the
Reactor. The cracked products in the vapour phase
goes from Reactor to the fractionator’s through
Reactor Vapour line. Coke is deposited on the
 circulating catalyst in the reaction zone. Spent
catalyst flows from the Reactor to the Regenerator
where coke is burnt off with controlled combustion
air. The heat of combustion raises the catalyst
temperature to 640 – 660 o C range. This hot
catalyst supplies heat to the reactor.

➢ FRACTIONATION SECTION:- In the fractionation

section, the Reactor vapours are fractionated into
Wet Gas, Unstabilized Gasoline, Heavy Naphtha, Light
Cycle Oil (LCO), Heavy Cycle Oil (HCO) and Clarified
Oil (CLO).
➢ GAS CONCENTRATION SECTION: - Compressed Wet
Gas and Unstabilized Gasoline go to Gas
Concentration Unit where they are separated into
Fuel Gas, LPG & Stabilized Gasoline, LPG and
Gasoline are washed with caustic in the treating
section of Gas Concentration Unit. Amine treatment
of LPG is done prior to caustic wash. For the
convenience of description, process flow of the entire
unit can be divided into six sections;

a. Feed Pre-heat Section

b. Catalyst Section
c. Fractionation Section
d. Gas Concentration Section
e. Caustic Treatment Section
f. Steam Generation Section
FEED PRE-HEAT SECTION
FEED CHARGE DRUM :-
Hot Vacuum Gas Oil from VGO HDT/Feed Preparation
Unit and VDU is
received in feed charge drum . Balance feed stock
comes as cold feed from storage tank
through feed pumps .
Flow controller which is cascaded with level controller
20-LC-121 on 820-V-04 controls the level of 820 V 4.
4.2.2. HEAT EXCHANGER TRAIN : -
Pumps 820-P-02A/B under flow indicator 820-FI-288
pump raw oil from 820-V04 to heat exchangers. A 4”
tapping provided U/S of 820-FI-288, caters to:

i. Filling of the system during start up

ii. Flushing and gland seal oil system ( 1-1/2”)
iii. Torch oil to regenerator ( 1-1/2”)
iv. VGO to CO – Boiler as IFO (1-1/2”)

The raw oil passes through heat exchangers in the

following sequence and gets heated to 300-315 0C.
i. Heavy Naphtha Exchanger 820-E-15
ii. Circulation LCO Exchanger 820-E-14A/B
iii. Clarified Oil Exchanger 820-E-05
iv. Circulating HCO Exchanger 820-E-02A/B
v. Slurry Exchanger 820-E-03 A/B/C
FEED PREHEATER :-
Raw oil from 820-E-3C goes to feed preheat furnace
820-F-01. Feed to furnace enters into two passes through
flow control valves, which are reset, separately by 20-FC-
90 and 20-FC-91. The temperature of raw oil ex-furnace
is controlled by 2 TC 2504, which resets the control
valves on fuel gas supply. Raw oil ex.820 FO1 meets with
recycle stream of HCO under flow controller 820 FC 166
and goes to riser in four OPTIMIX nozzles. Combined feed
is atomized by steam, which is controlled by 2 FC 7611.
Hot slurry from MCB pump 820 P-03A/B is recycled to
riser under flow controller to 2FC 7618 and enters into
the riser through two nozzles located above combined
feed nozzles. It is atomized by steam controller 2FC7605.
The combined feed goes to reactor riser or column
through 2-HC7608A/B. A selector switch opens 820-HC-
7608A to riser and closes 2-HC-7608B to 820-C-01
during feed cut in period. To cut out feed to riser,
selector switch is moved to the second position, which
closes 2-HC-7608A and opens 2-HC-7608B to 820-C-01
thus the reactor is bypassed by diverting feed to column.
With the bypassing of feed, Slurry recycle and VB
Naphtha to reactor also get automatically shutoff. For
slurry introduction to riser, 2 HS 7608E to be reset.
Visbreaker naphtha is introduced at the bottom of riser
by flow controller 2FC 7203. Lift gas introduction
provision is also there at the bottom of the riser.
Modifications:
Hot VGO from the upstream of furnace (820 F-01) has
been taken as seal flushing material for main
fractionator bottom pump (820 P-3A/B) instead of HCO.
With HCO flushing, frequent seal failure was observed.

CATALYST SECTION :-
REACTOR 820-RX-01: 19 The combined feed meets with
hot catalyst from regenerator at the bottom of reactor
riser. The resulting catalyst-oil vapour mixture is raised
to the desired reaction temperature by using sensible
heat of catalyst. Almost total cracking reaction takes
place in the riser. Residence time in the riser is around 3-
5 seconds. Lift steam is also introduced at the bottom of
the riser through flow controller 2FC-7201 and 2FC-7202
to lift the catalyst/oil mixture inside the riser. The oil
vapours disengage from the catalyst as soon as they
leave the VSS (Vortex Separator System) and leave the
reactor through 3 nos. single stage cyclone separators
suspended from reactor top head. The catalyst from the
cyclones returns to the dense phase of reactor, through
cyclone dip legs.

REACTOR STRIPPER:-
Catalyst descending from the reactor passes through the
stripper, which surrounds the upper portion of the riser.
Catalyst flows over the baffles counter current to the
rising stripping steam. The steam displaces oil vapour
from the catalyst particles and returns these vapours to
the reactor.

REGENERATOR :-
 In the process of cracking in the riser / reactor, coke
deposition takes place on the catalyst surface. With the
result, the active surfaces of catalyst reduce. To
regenerate the catalyst, the deposited coke is burnt off
by air in the regenerator. The atmospheric air is taken
though a blower, 820-K-01, at ambient conditions and
discharged to the regenerator at 220-250 oC. The excess
air is vented to atmosphere by 2FC 6819. This c/v
controls the airflow through regenerator depending upon
the cyclone temperature set in the RMPC. The
regenerated catalyst leaves the regenerator through the
regenerator standpipe. A slide valve (RCSV), which is
reset by 2TC 7316, controls the temperature of the
reactor. An expansion joint is provided on this standpipe.
The regenerated catalyst goes to the bottom of the
reactor riser and is lifted by the lift steam/ VB naphtha.
As the catalyst rises up the riser it mixes with the
combined feed and slurry recycle streams, which are
injected through their respective nozzles. Thus catalyst
circulation is established between reactor and
regenerator. Normal catalyst circulation rate is 16-22
MT/minute.

ORIFICE CHAMBER :- The coke is burnt in the

regenerator to form a mixture of carbon monoxide and
carbon dioxide. The gases containing 6-8 % ‘CO’ come
out of 3 sets of two stage cyclones in regenerator and
leave from the top. A double disc slide valve (DDSV)
located on the flue gas line is reset by 2PDC 7346. DDSV
controls the differential pressure between the
regenerator and reactor. Gases are passed through an
orifice chamber, 820-ME-3, where a series of restriction
orifices reduce the pressure of gases so that differential
pressure across DDVS is reduced which in turn reduced
its erosion.

FRACTIONATION SECTION: -
The cracked oil vapours at around 490-511oC from the
reactor top are fractionated into different cuts in this
section. Vapours enter the main fractionating column
820-C-01 at the bottom. The column internals consist of
08 valve trays and 06 packed beds.

OVERHEAD SYSTEM: - Vapours from the column top are

condensed in air fin coolers 820-E-12 A to L and further
cooled in trim cooler 820-E-13 A/B/C/D. Condensate and
uncondensed gases are received in receiver drum 820-V-
05. A part of liquid hydrocarbons are put back as reflux
to 820-C-01 top with the help of pumps 820-P-09 A/B. A
control valve, 20 FC-210 on this line controls the top
temperature of 820-C-01 with the help of 20-TC-153.
Rest of the liquid (unstable gasoline) is pumped by 820-
P-10 A/B to 830-C-01 of GCU under level controller 20-
LC-204, which controls 820-V-05 levels. Gases from 820-
V-05 go to WGC knock out drum 830-V-16 where the
entrained liquid, if any, is separated from gas. Dry gas
then goes to wet gas compressor 830 KO1A (Turbo
driven) and 830 K01B (motor driven). A spillback from
the 1st stage discharge of compressors 830-K-01A/B
joins the vapour inlet line of 820-E-13A/B/C/D.
GAS CONCENTRATION SECTION: -
The function of GCU is to separate lean gas, LPG and
stabilized gasoline from unstabilized gasoline and wet
gases obtained from main fractionators overhead drum
820-V-05. Wet gases from 820 V-05 top are routed to a
knock out drum 830 V-16 where any free liquid gets
separated and reasonably dry gas enters the first stage
of compressors 830 K 01A and B through load sharing
flow controller XIC3801 and HIC 3901 respectively.

GAS COMPRESSOR :-
Compressed gas from 1st stage of 830 K01A goes to
following at around 6 Kg/cm2 pressure. It enters the
interstate cooler 830 E-01A/B Before entering the cooler
it meets with a wash water stream from wash water
pumps 830-P-02 A/B. Normally, wash water flow is 7-
10% of raw oil by volume. Wash water reduces the effect
of hydrogen blistering.

PRIMARY ABSORBER (36 trays):-

The function of the Primary Absorber 830-C-01 is to
obtain a sharp separation of propane, propylene, butane
and butylenes from rich gas ex. 830-V-03 by the method
of absorption. Absorption medium used is unstabilized
gasoline from 820-V-05 and stabilized gasoline from 830-
C-04:
1. The rich gases from 830-V-03 enter Primary Absorber
830-C-01 below the bottom most tray no.1.
2. Stabilized gasoline from stabilizer, pumped by 830-P-
06 A/B enters on Top tray under a flow control valve,
which is reset by 30-FC-59.
3. Unstabilized gasoline from 820-V-05 enters on the
28th tray. Provision is also there to route this stream on
then 36th tray of 830-C-01.
4. Heat of absorption is removed by circulating a stream
of rich gasoline, from tray no19, through the water
intercooler 830-E-04. Cold stream is returned on tray no.
18.
5. Gaseous hydrocarbons leaving 830-C-01 top flow to
Secondary Absorber 830-C02. 830-P-05/04B pumps rich
gasoline to HP cooler 830-EM-2A/B under level controller
30-LC-54 from the bottom of the absorber.
6. Sour water from 830-E-04 boot goes to 820-EM-12 A
to L along with HP receiver sour water. Note: If water
from 830-E-04 hydrocarbon side is not drained properly it
may obstruct flow of liquid hydrocarbons from 19th tray
to 18th tray and heat removal from the column will be
affected.

SPONGE ABSORBER (20 trays ):-

The function of this column is to recover the valuable
LPG components from the gas, which are not absorbed in
830-C-01. The absorption medium is LCO from main
fractionating column.
1. Gases from 830-C-01 enter the bottom of 830-C-02
below 1st tray.
2. LCO from 830-E-07, after exchanging heat in 830-E-
05 and getting cooled in 830-E-06 is pumped by 830-P-
07 A/B to the top of absorber. 830-FC-71 controls flow of
this stream.
3. Unabsorbed lean gas from the top 830-C-02 flows to
knock out drum 830- V-11. From 830-V-11 the gas goes
to GRE fuel gas system under pressure controller 30-PC-
63, which controls GCU pressure. This gas can also be
routed to flare. One 2” fuel gas line from upstream of
30PC63 is given for DG points for Reactor riser.
4. The rich sponge oil from the bottom of 830-C-02
returns to main fractionators through 830-E-05 under 30-
LC-65. This controls the level at the bottom of Sponge
Absorber.

AMINE ABSORBER (10 trays):-

The function of this column is to remove hydrogen
sulphide from LPG.
1) LPG from 830V05 enters absorber bottom below 1st
tray.
2) Lean Amine ex. SRU enters absorber top above 10th
tray through 3FC 1901.
3) Hydrogen Sulphide free LPG leaves 830 C05 from top
and enters amine settler 830-V19 and goes to 830-V-
09A/B/C for caustic and water wash treatment. Carried
over Amine from 830-V-19 goes to ABD (830-V-20) from
where 830-P-20 pumps it to SRU.
4) Rich amine leaves 830-C05 bottom under lever
controller 3LC-1902. One shut off wall (SDV 1902)
provided down stream of 3 LC-1902, which will close at
low level (20%) of 830-C05 bottom to avoid LPG carry-
over to SRU.
 CAUSTIC TREATING SECTION: -
CAUSTIC TREATING FOR GASOLINE:
Gasoline from debutaniser bottom trim cooler 830-E-11
comes to the caustic wash vessels 830-V-6 A/B, which
operate in series. “DM water wash” replaced “Caustic
wash” in 830V06B since 2007. This is done to avoid
caustic slippage to MSQ Unit because Caustic is more
detrimental to the MSQ catalyst than H2S. Dedicated DM
Water line to 830V06B facility provided in Aug’’08.
Treated gasoline from the top of 830-V-06 A/B goes to a
caustic settler 830-V-07, where caustic entrained with
gasoline is settled and 830V-07B (Gasoline sand filter) ,
caustic free gasoline pumped by 830-P-16 A/B to GRE
MEROX via control valve 30-LC-98. This controls 830-C-
04 bottom levels. An indicator 30-FI-132 is also located
on gasoline R/D . 1 ½” line at the bottom of 830-V-06
A/B serves both for removing the spent caustic as well as
addition / make up of fresh caustic in the system. The
spent caustic is routed to Central ETP via GRE for final
disposal. 830P17A/B are provided for caustic circulation
of vessels. A provision is also there to bypass the vessels
30-V06 A/B and 30-V07 for MSQ Unit.

LPG CAUSTIC WASH: -

The LPG produced in cracking reaction of FCCU is prone
to contain sulphur in one form or the other which is
undesirable. Hence it is treated with caustic solution so
as to conform to specifications before being sent out of
the unit.
 Process flow diagram
1) ATMOSPHERIC UNIT
2) DELAYED COKER UNIT
3) SULPHUR RECOVERY UNIT
4) FLUID CATALYTIC CRACKING