Summer Internship

at
Haldia Petrochemicals Ltd.
Submitted by-
Jyoti Prakash Behera
Roll no-11CH10021
About The Company
Haldia Petrochemical Ltd. is a Naphtha based petrochemical Industry.
The industry consists of Naphtha cracker unit and associated plants.

Major products :-
LLDPE, HDPE, Poly-Propylene and Motor Spirit.
Introduction
My Internship was based on the Process of Naphtha Cracker Unit.
Thermal-cracking of Naphtha is done followed by separation of required
cuts.
Naphtha Cracker Unit is a very crucial unit, as this unit is responsible for
production of raw material of other associated plants (HDPE, LLDPE, PP,
NCAU etc.) in the factory.


Block Flow Diagram
of
Naphtha Cracker Unit










Feed Handling
Section
Heater Section Quench Section
Compressor section
CBFS
Cold Section

H2

Ethylene
Hot Section
C3H6
C4-Mix
RPG
Brief Description of Process
The Naphtha from feed handling section will be fed to furnace for thermal
cracking at approximately 815 C.
At Quench Section the cooling of the gas is to about 32 C .
The product of Quench Section will be used to get CBFS out of it the
effluent will be fed to Compressor Section.
At the Compressor Section the charge gas gets compressed from (about) 0.4
to 37 Kg/cm2 maintaining 16 C as its entry and exit temperature . Interstage
coolers are used for cooling in between each stages.
The high pressure effluent stream will be dried then fed to cold section where
separation of Hydrogen, Methane and Ethylene will take place.
This Hydrogen and Methane are used as fuel in the furnace as per requirement.
The outlet stream will be sent to the hot section for extraction of Propane and
finally separation of light Gasoline from C4-mix takes place. Light gasoline in
blended with heavy and middle gasoline to obtain RPG.
The C4-residue is used to extract other useful product like Benzene,D
Introduction to Project
(Calculation of Furnace efficiency)
Furnace was made up of Fire bricks capable of sustaining 1200 C inside
temp.
Naphtha was pre-heated in the upper part of furnace then it is heated to 815
C in the lower part(radiation zone) for cracking.
Cracked Naphtha was used to produce steam followed by mixing with wash
oil for cooling purpose. Which is then further processed in Gasoline
fractionator.






Furnace Efficiency
Furnace efficiency is defined as the ratio of absorbed heat to fired heat based
on lower heating value of the fuel.
Factors Affecting Furnace efficiency:
Excess air supply.
Humidity in air.
Flue gas outlet temperature.
Inlet air and fuel temperature.
Flow rate of naphtha.

Calculation Procedure
Efficiency= (Total Heat Input- Total Heat Losses)/Total Heat Input
Here, total Heat Input= LHV + H
a
+ H
f

And Total Heat Losses= (Hr + Hs)
Where,
LHV = lower heating value of the fuel burned
H
a
= air sensible heat correction = C
pair
*(T
t
-T
d
))*kg of air.
H
f
= fuel sensible heat correction= C
pfuel
* (T
f
-T
d
)
H
r
=assumed radiation heat, H
s
=calculated stack heat loss.

Therefore,
Efficiency % = [ ((LHV + Ha + Hf)-(Hr + Hs)) / (LHV + Ha + Hf) ]*100




Design efficiency of the furnace,(around) = 95 %
Working on efficiency,(around) = 85 %
Calculatated efficiency,(around) = 80 %

Assumptions:
Radiation Heat loss and heat loss by stack gases are the only mode
of heat losses.
2% of Heating value of fuel is radiation loss.
Thank You!