 Crude oil is being separated

through distillation process into

makeable refined products, which is
otherwise not useful.
 REMARKS

1922-38 BATCH DISTILLATION 2,500 BPD

1939-86 DUBBS PLANT 5,500 BPD

1939 LUMMUS PLANT 5,000 BPD

1981 HBU-I DISTILLATION UNIT 20,000 BPD

1981 HBU-II DISTILLATION UNIT 5,000 BPD

1999 HEAVY CRUDE UNIT 10,000 BPD

1999 REFORMER COMPLEX 5,000 BPD

2001 CAPTIVE POWER PLANT 7.5 MW
2008 DCS INSTALLATION AT HBUs Convert Pneumatic control system into DCS System
2016 REFORMER COMPLEX Revamp Addition of new compressor & Heater
2016 PREFLASH & HBU-1 Revamp 32,400 BPD
2016 ISOMERIZATION Complex 7,000 BPD
2016 DHDS Unit 12,500,000 BPD
2016 SRU / HYU / AMU / SWU Units 15 Ton Per Day – 5,500Nm3/hr - 161 Nm3/hr - 7 m3/ hr
2016 New CAPTIVE POWER PLANT 18 MW
2016 Steam Generation System 126 TPH
Unit Type Unit Name Before Up gradation After Up gradation
Capacity Capacity

Crude Units:
Light Crude Distillation Unit HBU-I 20,000 BPSD 32,400 BPSD
Light Crude Distillation Unit HBU-II 5,000 BPSD 5,000 BPSD
Heavy Crude Distillation Unit HCU 10,000 BPSD 10,000 BPSD
Lummus Unit Lummus 5,000 BPSD 5,000 BPSD
TOTAL 40,000 BPSD 52,400 BPSD
Downstream Units
Hydrotreating and Reforming Reformer 5,000 BPSD
Isomerization Complex ISOM 7,000 BPSD
Dehydrodesulpherization Unit DHDS 12,500 BPSD
Sulphur recovery Unit SRU 15 Ton Per Day
Hydrogen Unit HYU 5,500 Nm3/hr
Amine Treatment Unit AMU 161 Nm3/hr
Sour Water Unit SWU 7 m3/ hr
Merox Unit Naphtha 4,400 BPSD
Merox Unit Kerosine 1,600 BPSD
Polymer Modified Bitumen Unit PMB
Unit Type Unit Name Before Up gradation After Up gradation
Capacity Capacity
Environment Control Units
Slant Ribbed Coalescers Two SRC Units 100 USGPM each
Dissolved Air Flotation DAF Unit 100 USGPM
Dissolved Air Flotation DAF 2 200 USGPM
Boiler House
Steam Boilers Five Boilers 12 Mtons/hr each
New Three Steam Boilers 26 Mtons/hr each
Instrument Air System
Instrument Air compressor Two Compressors 660 / 1000 SCFM
New Air compressor Compressor 1100 SCFM
Cooling Water System
Cooling Water System Three Cooling Towers
New Cooling Water System One Cooling tower
Flare System
Old Flare System
New Flare System
New Acid Gas Flare
Captive Power Plant
Old Power Plant Three Engines 7.5 MW
New Power Plant Three Engines 18 MW
 Crude receipts from various fields are stored and
blended in tanks keeping in view their
properties and processing plants design aspects.
 Crude received though two ways;
 Bowzers
 Pipelines
 Crude Oil storage capacity at ARL is about
5,50,000 barrels.
 By Road
Tank lorry / Bowzers
LPG
Export Naphtha
Solvent Oil
MTT
JBO
JP1
LSFO / HSFO
Bitumen/Asphalt
 By Train
LSFO
 By Pipelines
PMG
LWK
HSD
JP1
RFO
 Oil Movement-I divert products from plants to
their respective storage tanks.
 Monitor tank dips/levels, temperature and
specifications.
 Adjust products specification, sometimes blending
is also required.
 SRC Unit
Effluent treatment capacity = 100 USGPM
 DAF Unit
Effluent treatment capacity = 100 USGPM
 DAF 2 Unit
Effluent treatment capacity = 200 USGPM
 Independent section, Utilities Operation (UO),
manages required utilities for plants.
 Steam through boilers operation
 Cooling Water through Cooling Towers
Operation
 Fuel for furnaces
 Instrument / plant air by Compressors
 Caustic Soda for LPG treating and Merox
 General Utilities
Cooling Water
Steam
Process Water
Condensate
Soft Water
Fuel Gas
Fire Water
Fuel Oil
Drinking Water
Instrument Air
Garden Water
Plant Air
 Technical Information:
Boiler House Operations
Total number of Boilers = 8
Steam Production Capacity = 126 TPH
1. Three Fired Tube Boilers = 12 TPH each
2. Two Water Tube Boilers = 6 TPH each
3. Three Water Tube Boilers = 26 TPH each

Water / Air Operations

Raw Water Availability= 60,000 GPH
HBU-1 & Pre-Flash (32,400BPD)
HBU-2(5,000BPD)
HCU (10,000BPD)
LUMMUS (5,000BPD)

Total Capacity : (52,400BPD)

 Salt removal is necessary from crude, to
avoid equipment scaling and corrosion ;
this will decrease processing cost.
 Electrostatic desalters remove salts from
crude, these salts are mainly of Ca &
Mg.
 Removal of organic metallic compounds
like Co, Ni & Lead etc (by gravity).
 Desalter is a pressure vessel in which pre-
heated crude enters at high pressure.
 Through Turbulence, Coalescence and
agglomeration, salts are removed.
Distillation is a Separation technique, in
which a mixture is separated into various
components due to difference in their boiling
point.
 LPG
 Raw Naphtha (Further processing required)
 MTT/LWK/JP
 High Speed Diesel
 Light Diesel Oil
 Furnace Fuel oil
 Jute Batching Oil (Vacuum Distillation Product)
 Bitumen (Vacuum Distillation Product)
 Refromer complex consists of following
sections:

 Splitter
 Hydrotreator (NHT)
 Plareformer (SR)
 Raw naphtha form distillation unit is of no use.
It is further processed through naphtha
Hydrotreater and Platformer to make PMG,
which is a valuable and usable product.
Addition of New Plants
• Pre-flash Unit
• Isomerization (ISOM) Unit
• Diesel Hydro De-Sulfurization (DHDS) Unit
• Amine Treatment Unit / Sour Water Stripper
• Sulfur Recovery Unit (SRU)
• Hydrogen Plant (HYU)
• Captive Power Plant
• Boilers
ISOM complex consists of following sections:

 Splitter

 Light Straight Run Naphtha

Hydrotreater

 Penex-DIH
 The isomerization process upgrades the octane
number of light naphtha fractions and also
simultaneously reduces benzene content by
saturation of the benzene fraction.

 Isomerate product contains very low sulfur and

benzene, making it ideal blending component in
refinery gasoline pool.
 FEED SURGE DRUM
 MAKEUP GAS DRIERS AND FEED DRIERS
 HEAT EXCHANGERS
 Regenerant Vaporizer
 REGENERANT SUPERHEATER
 REACTORS
 STABILIZER
 NET GAS SCRUBBER
 DEISOHEXANIZER
 PUMPS & FIN-FAN HEAT EXCHANGERS
Process Objective:
 Sulfur is present in many forms in petroleum fractions:
mercaptans R−SH, sulfides R−S−R′, disulfides
R−S−S−R, polysulfides R−S,−R′, thiophene,
benzothiophene (BT), dibenzothiophene (DBT), and
their alkyl derivatives.
 Sulfur has to be removed from oil fractions for both
technical and environmental reasons. Regulations have
been introduced in many countries to reduce the sulfur
content in fuels, and the global trend for sulfur content
in diesel fuels is toward 10−50 ppm.
Primary Process Technique:
 In diesel hydrodesulfurization (DHDS) various types
of sulfur compounds convert in H2S form on the active
sites on the HDS catalyst surface.
 Feed Surge Drum
 Combined Feed Exchange
 Charge Heater
 Reactor
 Makeup Gas Compressors
 Recycle Gas Compressor
 Separator
 Flash Drum
 Stripper
 Stripper Receiver
 Stripper Re-Boiler
 PLANT CAPACITY & DESIGN

 Design capacity : 5500 NCMH

 Purity : 99.99 % mol

 Pressure : 30 kg/cm2

 Temperature : 38 °C

 Design margin : 10 %

 Turn down ratio : 30 %.

 PROCESS:

 Hydro Desulfurization
 Pre-Reforming
 Steam methane reforming
 Shift Conversion
 Purification (PSA)

FEED STOCKS:
Plant is design at two feed stock

1 - Naphtha (HSRN)
2 - Natural Gas
WHY SRU?
 To meet National Environmental Quality Standards
(NEQS)
 NEQS Specifications
 SOx in flue gases = < 1700 mg / Nm3
 Feed Preparation
 Main Combustion Chamber / Thermal Stage (3
chambers / heaters)
 CLAUS Stages (No. of Reactors = 3)
 SUPER CLAUS Selective Oxidation Stage/Reactor
 Thermal Incinerator
 Sulfur Pit
 Amine gas treating, also known as gas sweetening or acid gas
removal, refers to a process that uses amines solution to remove
hydrogen sulfide (H2S) and carbon dioxide (CO2) from natural
gas streams.
Gases containing H2S and CO2 are commonly referred to as
sour or acid gases. Sour gas is undesirable for several reasons.

1. Harmful to health and sometimes deadly if in contact

2. Extremely corrosive to pipelines
3. High degree of toxicity
4. Forms Sulfur dioxide (SO2) when burned which is another toxic
gas
5. Higher concentration result in death, TLV (Threshold Limit
Value) is 10 ppm.
 A typical amine plant consists of;

 Amine Contactor / Absorption Column

 Amine Regenerator
 Heat Exchangers
 Flash drum
 Re-boiler
 Filters
 Pumps
 Sour water
 Waste water produced during many refining
processes
 Typically contains;
 Hydrogen Sulphide (H2S)
 Ammonia (NH3)
 Must be removed before the water can be reused else
where in the refinery or sent to a waste water system
 LPG:
– Used as domestic fuel.

 Naphtha:
– Used as petrochemical feed stock.
– Used as Reformer feed for making PMG.

 Kerosene:
– Used as Domestic heater fuel.
 MTT:
– Used in paints as a solvent.

 JP-1/JP-8:
 Used as fuel in jets, Army aviation and commercial air
crafts.

 HSD:
– Used as fuel in jeeps and heavy Automobiles.

 LDO:
– Used in low speed engines.
 JBO:
– Used for making Jute.
– Also used as lubricating oils.

 Furnace oil:
– Used as fuel in Power Plant Generators.
 Bitumen/Asphalt:
– Used for Road making and water proofing.
PETROLEUM PRODUCT SPECIFICATIONS
PRODUCTS
LPG PMG Solvent Oil Kerosene JP-1 / JP-8 MTT HSD LDO JBO LSFO / HSFO
TESTS Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max Min Max
Color Pinkish +20 Saybolt - +20 - +21 Saybolt - - 3.0 3.0 - - 2.5**
Aromatics, Vol % - 20 Saybolt - 25 - 25 ASTM ASTM ASTM
Cetane Index 45 - 35 -
Cloud Point, °C , (Summer) - 9
(Winter) - 6
CFPP °C , (Summer) To be reported
(Winter) To be reported
Distillation, °C, IBP 45 - - - -
10% - 80 - 205 -
50% - 125 - - - 176 -
90% - 180 - - - 365
FBP - 205 - 120 - 300 - 300 - 215 - -
Flash Point, °C 35 - 38 - 35 - 66 - 54 - 121 66 -
Kinematic Viscosity @ 37.8°C - 14 12 25
Kinematic Viscosity @ 40°C 1.5 6.5
Kinematic Viscosity @ 50°C - 180
Lead Content, g/L
Pour Point, °C , (Summer) - 6 - 12 -
(Winter) - 3 - 9 21 - 24
Res. On Evap., Vol. %
Temp. at 95% Evap., °C - 4.4
RON 87 -
RVP @ 37.8°C, PSI,(Summer) - 9
(Winter) 70 200 - 10
Smoke Point, mm 22 - 19 -
Specific Gravity @ 15.6/15.6C To be reported To be reported - 0.82 0.775 0.84 To be reported - 0.92 To be reported - 0.96
Sulfur, Wt. % - 0.1 - 0.05 - 0.2 - 0.3 - 1 - 1.8 3.5 max HSFO /
Water, Vol% - 0.05 - 0.25 1.0- max LSFO
0.5
 Paving Asphalt Cutback Asphalt
60/70 80/100 RC-70 MC-70 RC-250
PRODUCTS Min Max Min Max Min Max Min Max Min Max
Flash Point, °C 232 - 232 -
Penetration @ 25°C, 1/10mm 60 70 80 100
Ductility @ 25°C, cm 100 - 100 - 100 - 100 - 100 -
Solubility, % 99 - 99 - 99 - 99 - 99 -
Volatility, wt. % - 0.8 - 1
Ductility after Volatility @ 25°C, 50 - 50 -
cm
Pen after Volat., 1/10mm 54 - 75 -
Water, Vol. % - 0.2 - 0.2 - 0.2
K/Visc. @ 60°C, mm2/s (cst) 70 140 70 140 250 500
Distillation, %age by Vol.
IBP – 190°C 10 - - - - -
190°c – 225°C 50 - 0 20 35 -
225°c – 260°C 70 - 20 60 60 -
260°c – 315°C 85 - 65 90 80 -
Residue from Distillation to 55 - 55 - 65 -
360°C, Vol %
Operator Training Simulators (OTS) allow
operators to train on a computer in an
environment identical to the control room.
OTS training tools provide in-depth process
understanding through accurate simulation
models of the plant and aid in process analysis
and operator training. This provides safe and
efficient operations that benefit the plant, the
workers and the overall profitability of the
company.
ARL has Operator Training Simulators (OTS) for
the following process units:

 HBU-I: 32,400 BPSD Crude Distillation Unit, including Pre-Flash

Unit.
 UOP Licensed Reformer complex (after revamp) comprising
Naphtha Splitter, Naphtha Hydrotreater (with recycle),
Platformer.
 UOP licensed Isomerisation Complex (Naphtha Splitter, Light
Naphtha Hydrotreater, Penex Unit, De-Iso Hexanizer).
 UOP Licensed DHDS (Diesel Hydrodesulphurization Unit).
Thanks for your Attention
&
Any ? Please