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Guwahati (Assam)
Barauni (Bihar)
Baroda (Gujarat)
Haldia (W.B.)
Mathura (U.P)
Panipat (Hr.)
Koyali
Paradweep (Orissa)
Bongaigaon (Assam)
Digboi (Assam)
The combined rate capacity of these ten refineries is 49.30MMPTA.
IOC accounts for 42% of Indias total refining capacity.
HALDIA REFINERY (IOCL)
Haldia Refinery, one of the seven operating refineries of Indian Oil, was
commissioned in January 1975. It is situated 136 km downstream of Kolkata in the
district of Purba Medinipur, West Bengal, near the confluence of river Hooghly
and Haldia.
From an original crude oil processing capacity of 2.5 MMTPA, the refinery is
operating at a capacity of 5.8 MMTPA at present. 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. 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.
Haldia Refinery is the only coastal refinery of the corporation and the lone lube
flagship, apart from being the sole producer of Jute Batching Oil. Diesel Hydro
Desulphurization (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 Fluidized 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. A Catalytic Dewaxing Unit (CIDWU)
was installed and commissioned in the year 2003 for production of high quality
Lube Oil Base Stocks (LOBS), meeting the API Gr-II standard of LOBS.
Finished products from this refinery cover both fue l oil products as
well as lube oil products.
LPG
Naphtha
Motor Spirit ( MS )
Mineral Turpentine Oil ( MTO )
Superior Kerosene ( SK )
Aviation Turbine Fuel ( ATF )
Russian Turbine Fuel ( RTF )
High Speed Diesel ( HSD )
Jute Batching Oil ( JBO )
Furnace Oil ( FO )
FCCU
GO
SO CBFS
Ext. 70 N GR-II
V V LO / IO / HO
RCO
D D FEU SDU HFU
150 N GR-I / II
U U NMP
500 N GR-I / II
DAO S.Wax 850 N
1 2
150 BS GR-I/II
PDA
CDWU
Asp.
SR
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Fig:
01
FIRE & SAFETY:
FIRE:
Fire is a rapid , self sustained oxidation process accompanying by the release of
energy in the form of heat and light of varying intensity.
Fire results from the combustion of fuel, heat & oxygen.
Fire triangle:
Three elements are necessary for initiation of fire:
1. Fuel in the form of vapor, liquid or solid.
2. A source of ignition is sufficient to initiate and propagate the fire.
3. Oxygen is sufficient proportion to form a combustible mixture.
Combustion process is observed in two modes:
For flaming combustion to occur, solid or liquid fuel must be converted into
vapor which then mixes with air and reacts with oxygen.
Smoldering combustion, on the other hand , involves a reaction between
oxygen and the surface of the fuel: this a complex process and in general occurs
with solid fuels.
FIRE TRIANGLE
OXYGEN HEAT
Fig-02
FUEL
EXTINGUISGING MEDIA: Foam, carbon-dioxide, dry chemical powder,
water.
SAFETY:
The main & utmost thing , which is to be known to all is the safety during working
in an industry. A person in an industry should well aware about the safety rules to
keep him safe & others from any unwanted mishap.
The main principle points which one should keep in mind are:
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.
f. Workers should keep in mind that not to work near inflammable gases.
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 fire is.
[Note: During fight with fire with CO2 one should always about the direction of air
flow, because one may feint if he is in wrong direction.]
FUEL OIL BLOCK (FOB):
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)( 60:40 wt ratio) are processed. The capacity has been
increased from 2.5 MMPTA to 6.0 MMPTA.
Fuel oil block produces fuel oil from crude and this block consist of eight
subunits as given below:
Crude at
180-200oC
Pref-
Crude oil ract-
Crude oil
Crude Pre heat Desalter 2nd heat iona-
exchanger 120- 95% exchanger tor
1300C desalted
Heat
Exchanger
Kerosene/ATF
140-271oC/140-240oC
Atmospheric
KHDS (UNIT Kerosene Crude oil 350-
distillation
_23) storage unit 360oC
HSD
Jute batching oil
storage 320-360oC ( JBOC)
JBO
Storage 320-380oC (JBOP)
VDU
very low boiling Hydrocarbon( C3-C4)
Gas plant unit D
UNIT-12
Total
S gasoline VB Gasoline H2S
IBP-
C5-90oC boiling
140oC Stabilizing hydrocarbon cuts
column Gasoline
C Caustic
merox unit Naphtha
wash
storage
C5-1400C Naptha
cuts redistilla
-tion
column
Excess ( 90oC-
140oC) boiling
hydrocarbon cuts
Catalytic
reforming 90-140oC boiling
unit (unit22) hydrocarbon cuts
Fig-04
De - Propane
D ethanizer
mercaptan
H2S+Amine Propane
Deasphalt unit
LPG MEROX De-
DEA Wash treatment Propanizer
plant
Octane
improvement
Mercaptan free LPG
Motor spirit
Fig-05 Caustic butane
blending
separation unit
LPG
storage
PRINCIPLE OF OPERATION:
Before feeding to the desalter, crude oil is heated to 120oC-130oC in the first set
of pre heat exchangers. In the desalter, the crude is desalted to an extent of 95%.
Crude is then heated to 260oC-265oC in the second set of heat exchangers. It is
thereafter heated to 350-360oC in furnace and thereafter fractionated in
Atmospheric Distillation Unit to the following streams having separate B.P.
ranges.
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.
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.
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.
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 vapor 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 vapors and water goes to
accumulator 11b01 where 1.8-2.8 kg/cm2 pressure is maintained.
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 stabilizer 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. vapor 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.
PROCESS DESCRIPTION
There are three sections in this plant:
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.
Feed is heated by depropaniser bottom in heat exchanger and enters the 14th tray
of column. Overhead vapor 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.
Caustic Regeneration: Caustic from merox unit is heated in a double pipe heat
exchanger and enters the oxidizer vessel where mercaptans get oxidized to
disulphides and mixture goes to disulphide separators where the disulphide oil is
separated as two layers. Regenerated caustic is sent for recirculation.
Amine regeneration: Objective of this unit is to remove H2S from H2S rich amine
received from DEA wash column from gas plant. From Amine absorber of lube
hydro finishing unit and fuel gas amine absorption unit H2S is stripped off from
amine with the help of steam. Lean amine after removal is recirculated to gas
plant, fuel gas amine absorption and LUBE HUF, stripped H2S is sent to sulphur
recovery unit for sulphur production.
THEORY OF HYDROTREATMENT:
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. 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.
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 car bozo, 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.
METAL COMPOUNDS: These may be present as contaminants of Na,As, Pb, Ni,Cu
etc. Allowable limit is As: 1 ppb ( Pb + Cu ) : 1ppb
WATER: As water is also a poison for reforming catalyst, its content should be
within specified limit in reforming feed.
OXYGEN COMPOUNDS: Sometimes phenolic compounds are present in naphtha
and are removed as water. Maximum allowable limit of water is 20 ppm.
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.
PRODUCT:
The unit can produce three different qualities of kerosene:
Superior Kerosene ( SK )
Mineral Terpentine Oil ( MTO )
Aviation Turbine Fuel ( ATF )
PROCESS DESCRIPTION:
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.
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 regulation 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.
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 vapor is sent to Hydro finishing Unit of Lube Oil block.
Another part is recycled along with makeup gas and compressed by two parallel
reciprocating compressor 23K01A/B.
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. The entire stripper bottom is pumped by
23P03, cooled and sent to storage as finished product.
The stripper overhead vapors 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.
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 vapor from the knockout drum are
compressed in the second set of compressors and cooled in a water cooler. The
vapor separated liquid hydrocarbons are sent to fuel gas system or amine unit.
The condensed hydrocarbons are drained manually.
DHDS BLOCK:
RESID FLUIDISED CATALYTIC CRACKING
UNIT(unit 17/18/19):
Fluid Catalytic Cracking Unit consists of the following sections:
Feed Preheat Section
Reactor / Regenerator Section
Flue Gas Section
Catalyst handling section
Main Fractionators Section
Product Recovery Section
Amine Treating Section
5. Aromatic saturation:
Aromatic saturation reactions are the most difficult and are very exothermic.
Benzene + H2 = Cyclohexane
6. Metal removal:
Metals are retained on the catalyst surface by a combination of adsorption and
chemical reaction. Removal of metals normally occurs from the top of the catalyst
bed and the catalyst has a certain maximum tolerance for retaining metals.
Metals contained in the crude oil are usually nickel and vanadium. Iron is found
concentrated at the top of the catalyst beds as iron sulphides, which are corrosive
products. Sodium, calcium and magnesium are present due to the contact of the
bed with salted water or additives. Improper use of additives, to protect the
fractionators overhead systems from corrosion or to control foaming, accounts
for the presence of phosphorous and silicon. Lead may also deposit on the hydro
treating catalyst beds 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 a guard bed of catalyst specially designed for
demetallization.
7. Halide removal:
Organic halides such as chlorides and bromides are decomposed in the reactor.
The inorganic ammonium halide salts, which are produced when the reactor
effluent is cooled, are dissolved by injecting water into the reactor effluent, or
removed with the 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-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.
FEED CHARACTERISTICS
The feedstock of the SRU is a mixture of the "Acid gas ex ARU" and "Acid gas ex
SWS". The quality and quantity of H2S feed to the unit will vary depending on the
shutdown of the various preceding units. The unit should be capable of converting
99% wt. of the H2S contained in the feed streams to sulphur in all cases.
PRODUCT CHARCTERISTICS
The product sulphur meets the following specification after degassing :
State: liquid sulphur
Colour: bright yellow
Purity: minimum 99.9% on dry basis
H2S content: 10 PPM wt. maximum
CLAUS SECTION
The main reaction in this section takes place at main burner
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 the Claus reaction, sulphur is formed in the main burner
and reaction chamber.
SUPERCLAUS SECTION
In this section partial oxidation of H2S takes place according to the reaction
equation given bellow
2 H2S + O2 2/8 S8 + 2 H2O + Heat
PROCESS DESCRIPTION:
CLAUS SECTION: By the reactions described before, 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 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 1st 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 and 3rd reactor stages, the H2S and SO2 again react to form sulphur
but this time at lower temperatures.
In the SUPERCLAUS 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 downstream of the 3rd reactor stage, the amount of H2S in the range of 0.5
0.7 volume % and the SO2 concentration is as low as possible.
Before entering the 1st 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 1st reactor is routed to 2nd sulphur
condenser.The process gas flow is next routed to 2nd steam reheater and then to
2nd 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 reheated,
and then passed to the 3rd reactor where 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 the fourth steam re-heater then passed to the reactor. Before it enters the
reactor, a controlled amount of air is added. Proper mixing is obtained in a static
mixer. In the reactor sulphur S8 is formed according to the reaction mentioned
before.
The formed sulphur is condensed in the 5th sulphur condenser. A
Sulphur coalescer is installed downstream of the last sulphur condenser to
separate entrained sulphur mist.
The sulphur condensed and separated in the condensers and coalescer is drained
via the sulphur locks and the sulphur cooler into the 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 vapour to SO2 in presence of
oxygen. After the gas is cooled in incinerator, waste-heat boiler and super heater
it is routed to the stack. In the incinerator and waste-heat boiler, MHP steam is
produced and in the superheater 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 polysulphides (H2SX). Without treatment of the 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 130OC to 4.4 volume % H2S at ambient condition. The
shell sulphur degassing process has been developed to degasify liquid sulphur to
10-ppm wt H2S/H2SX that is the safe level to avoid exceeding the lower explosive
limit.
The function of this process is to enhance the decomposition of polysulfide 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 the sulphur.
In this way, the H2S content is reduced from approximately from 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.
NAPTHA
PRODUC
T
LPG
ISOMERIZ
SR NAPTHA
NAPTHA NHDT ATION +
SPLITTER UNIT 85
DIH + LPG
UNIT 85 RECOVER I
Y UNIT 86 S
HYDROGE
O N
LPG
M
E
NHDT &
REFOR R
CRU
MATE A
UNIT 21 & SPLITTE T
UNIT 22 R E MS
PRODUCT
UNIT 85
FCC FCC GASOLINE HEART
FCC CUT
GASOLIN SHU
E GASOLINE
UNIT SPLITTER
87 UNIT 87
HEAVY FCC
GASOLINE
PRIME G+
SELECTIVE
PYROLYSIS DESULPHURIZA
GASOLINE TION UNIT
Fig: 06
UNIT 87
Visbreaking Unit U 37
SPINDLE OIL
LIGHT OIL
REDUCED CRUDE
VDU
OIL INTERMEDIATE OIL
SHORT RESIDUE
Fig:07
PURPOSE:
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 grades LOBS feed stock or FCCU feed.
Inter Oil ---- 500 N grade LOBS feed stock or FCCU feed.
Heavy Oil ---- 850 N grades LOBS feed stock or FCCU feed.
Vacuum Residue ---- Feed stock for PDA unit.
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.
Operating conditions:
MIXIN
PROPANE
G STEAM SOLVENT
TANK
EVAPORATION
PROPANE
TOWER
VESSEL
H.E. EXTRACTION
S COOLER TOWERS STEAM+SOLVENT
O
L
V
E ASPHALT + LITTLE
N FURNAC AMOUNT OF SOLVENT
T
E STRIPPER
KO
STEAM+SOLVENT
Pot
EVAPORATION
TOWER
VM STEAM
VM STEAM
This unit produces deasphalated oil (DAO) by removing asphalt from short residue
obtained from Vacuum Distillation Unit (VDU).Solvent extraction process is
chosen for removal of asphaltic material from short residue and deasphalted oil
(DAO) is recovered. 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 processing as bright stocks. Asphalt is sent as fuel to TPS and as feed
stocks to Bitumen and Visbreaking units.
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.
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 vaporized 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 vapors pass overhead
and DAO products. The steam and solvent vapors 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 OC in the furnace
F1 in order to vaporize most of the solvent and to prevent foaming in the flash
tower. Vaporized 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 extraction column
temperature and pressure gradient and solvent feed ratio are the most important
among them.
1. Extraction temperature and temperature gradient: Above 38 OC propane has a
negative temperature co-efficient in respect of asphalt and resin solubility. The
top and bottom temperature are maintained at 68 OC and 52 OC respectively.
These temperatures are raised depending on the feedstock and product quality
that are desired. Increasing the top temperature will precipitate and further
quantity of asphalts of 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 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 , C-2 . Solvent composition is
maintained for steady product quality.
RAFFINATE
FEED
STOCK DE-AERATOR
FURFURAL
VM
STEAM
EXTRACTOR
Fig:09
FURFURAL
EXTRACTION UNIT EXTRACT
(UNIT- 33)
QUALITY MONITORING:
Raffinate: KV @ 100oC, RI, CCR.
Extract: Density.
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. Neutralization with Na2CO3 solution
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 OC .
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 .
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 114OC
enters the cooler operating at 100 mm Hg from, where liquid furfural is pumped
at 60 OC 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
vapor 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 vapor from the extract pressure flash tower at 180 OC are cooled in
drying solvent tower to 165OC. The furfural vapors 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 vapor 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.
7. Neutralization with sodium carbonate solution: To prevent corrosion sodium
carbonate solution is injected into following circuit:
Water vapor and furfural vapor
Furfural vapor and water vapor
Quality Monitoring:
DWO: Pour point, Flash point, KV @ 100oC & 40oC
Objective:
To remove paraffinic hydrocarbons to remove paraffinic hydrocarbons from the
extract to the low pour point to make it suitable for low temperature application.
PROCESS:
Extraction and crystallization to achieve dewaxing with the addition of SDA
followed by filtration and solvent recovery.
ROTARY
SECONDARY
LIQUID NH3 REFRIGERANT DILUTION SOLVENT VACUU
FEED STOCK M
FILTER
TRAIN OF DP
CHILLERS
SDA DOSING WAX TO FCCU
(PRIMARY
DILUTION
SOLVENT) SOLVENT +
DWO
STRIPPER
SOLVENT
DRYING VM STEAM
TOWER
SOLVENT RECOVERY
Fig:10
SECTION
Solvent:
MEK & Toluene in equal proportions. Toluene is oil solvent & MEK is antiwax solvent.
Antiwax Solvent:
Antiwax solvent, also called wax-rejecter (MEK) is used 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 impose
highest solvent effect on oil and little solvent effect on wax.
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.
PROCESS DESCRIPTION:
The unit is subdivided into the following sections:
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.
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 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 vaporized by the
overhead vapor 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-C-2). The overhead solvent of 34-C-3 vapors 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.
HYDROGEN GAS
AMINE
COMPRE CATALYTIC
ABSORBER
SSOR REACTOR
R
I
C
SEPARATOR H
OFF GAS
A
M
I
N
E
H2 GAS E
STRIPPING
COLUMN
K.O. DRUM
STRIPPING STEAM
PRODUCT Fig:11
PROCESS DESCRIPTION:
The following chemical reactions are involved:
Desulphurization: The sulfur is present in the feed under various forms such as
mercaptans, sulphides, disulphide 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.
Mild hydro-denitrification: Nitrogen is contained essentially in heterocyclic
compounds. When hydro finishing 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 cooler stability.
Amines RNH2 + H2 = RH + NH3
The ultimate products of hydro-denitrification are hydrocarbons and ammonia.
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.
feed
Heat
Bitumen
Air
Steam Water
Fig:12
OPERATING VARIABLES:
1. Column Temperature
2. Air blowing rate
3. Residence time
GAS OIL
FEED FURNACE
FRACTIONATOR
SOAKER
VISBREAKER
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.
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
Fig:14
EXTRACT R/D
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.
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 hydro treating reaction takes place where nitrogen is converted to NH3
while sulphur to H2S.Reaction is exothermic in nature, so interbred quenching is
done to maintain reaction temperature. The reactor effluents are cooled in
feed/HDT effluent heat exchanger 84-E-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. Vapor 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.
Low pressure recovery section: The liquids are stripped for the separation of
naphtha and lighter material from the de waxed oil stream. The vapors are
condensed and contacted with lean amine in the low pressure amine absorber,
for H2S removal, before discharge into the fuel gas header. The bottom products
are sent to the vacuum fractionators, where distillate and lighter material is
separated from the de waxed oil. The vapors are sent back to the furnace firebox.
The de waxed products are vacuum dried and cooled.
OIL MOVEMENT AND STORAGE (OM & S)
Imported crude brought by tankers stored in refinery storage tanks is processed
subsequently in different units and finished petroleum products are obtained
which are dispatched for marketing by tankers, barges, wagons, trucks and
pipelines. The process is a continuous one and the oil movement and storage
division of the production department plays an important role in maintaining
smooth continuous and rated operation of the refinery.
The broad functions of OM & S are listed as follows:
1) Receipt and storage
- Crude oil from tankers
- Intermediate and finished products from process units.
2) Preparation and supply of feed to various units
3) Blending of products
4) Dispatch of products
5) Supply of fuel oil to furnaces
6) Unloading, storing, supplying various solvents and chemicals to units
7) Recovery of steam condensate
8) Accounting of petroleum products and observing necessary customs and excise
formalities
9) Effluent treatment 10) Flare system operations
In addition to the above, the following auxiliary functions are also connected to
the OM&S division:
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.
Bay Products
1 Aviation Turbine Fuel
2 Naphtha
3 Motor Spirit
4 Aviation Turbine Fuel/PGMS
5 Superior Kerosene Oil
6 Superior Kerosene Oil
7 Jute Batching Oil
8 Jute Batching Oil
9 High Speed Diesel
10 High Speed Diesel
11 Aviation Turbine Fuel
12 Furnace Oil
13 Furnace Oil/Carbon Black Feed Stock
14 Furnace Oil
The loading is done mainly through automation. Some parts are done manually
when required. The instrument used is MERCURY METER and PD METER
(volumetric flow meter). The capacity of tank filled here are within 3000-6000 lt.
a) Commercial butane
b) Commercial propane
Handling of LPG requires basic knowledge of the nature and properties of LPG &
constant vigilance with the knowledge and experience. LPG is compressed into
liquid state for ease in storage and handling.
b) It has a typical vapour pressure of 7-8 kg/cm2 at 380C and density 0.54 gm/cc to
0.55 gm/cc.
e) While evaporation, liquid LPG picks up heat from the surroundings and cools
down; moisture present around it condenses.
i) Small quantity of its vapour in air can form a flammable and explosive mixture.
A very small quantity is also produced from Hydro cracker Unit (HDCU)-unit91.
TYPES OF LPG:
TYPES STRAIGHT RUN CRACKED
FACTORS
PROPERTIES High octane number. Comparatively low
Lower calorific value octane number.
as compared to Higher calorific value.
cracked LPG.
USES Used as Auto LPG. For domestic use &
commercial purposes.
LPG RECEIPT AND STORAGE:
The LPG produced from the above mentioned sources is collected and stored in
LPG Storage Section. Well built pipe-lines with effective control valves, are used
for transfer of LPG from the respective sources in the plant. In Haldia Refinery the
storage equipments for LPG are:
a) Bullets
b) Horton Spheres
c) Mounded Bullets
All these storage units have : Two safety valves, pressure & temperature gauge,
and have three control lines inlet line, outlet line, vapour balance line.
STORAGE UNITS:
Horton Spheres
These are large spheres of 1500 m3 capacity used in Haldia Refinery of IOCL for
storage of LPG.
The significance of the design of Horton spheres are:
(i) The spherical shape ensures less vapour formation since least area is
provided, for same volume of liquid LPG, as compared with the other shapes
of containers. Thus minimizing pressure build up inside the spheres and
reducing chances of enormous explosions.
(ii) Uniform pressure distribution.
With these significances, Horton spheres stand as a more effective storage facility
than Bullets. But it was seen that a problem arose as the supportive legs of the
Horton spheres are susceptible to breakage.
Mounded Bullets
Mounded Bullet storage comprises a cylindrical shaped vessel surrounded by
stones, sand, etc. to absorb the impact of any accidental explosion. It also does
not have the problem of support as there was in Horton spheres. With 59m
length, 6m diameter and 1500m3 capacity of the cylindrical vessel, Haldia refinery
of IOCL has 3 such mounded bullets. Its design pressure is about (14.5kg/cm2) (g).
They are also subjected to cathodic protection to restrict rusting of the vessel
body.
EFFLUENT TREATMENT PLANT (ETP):
An effluent treatment plant has been installed for proper control of the unwanted
material and for effective recovery of the oil. In ETP the TSS (Total suspended
solid), BOD (Biological oxygen demand), COD (Chemical oxygen demand) of the
water is properly regulated before water is discharged in the surroundings.
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.
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 in aeration tank.
Fig: 15
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.
CENTRIFUGAL PUMPS:
CENTRIFUGAL PUMP
Fig: 16
A centrifugal pump is a rotodynamic pump that uses a rotating impeller to
increase the pressure and flow rate of a fluid. Centrifugal pumps are the most
common type of pump used to move liquids through a piping system. The fluid
enters the pump impeller along or near to the rotating axis and is accelerated by
the impeller, flowing radially outward or axially into a diffuser or volute chamber,
from where it exits into the downstream piping system. Centrifugal pumps are
typically used for large discharge through smaller heads.
Reciprocating pumps are those which cause the fluid to move using one or more
oscillating pistons, plungers or membranes (diaphragms).
RECIPROCATING PUMP
Fig: 17
Furthermore, they can be either "single acting" independent suction and
discharge strokes or "double acting" suction and discharge in both directions. The
pumps can be powered by air, steam or through a belt drive from an engine or
motor. This type of pump was used extensively in the early days of steam
propulsion (19th century) as boiler feed water pumps. Though still used today,
reciprocating pumps are typically used for pumping highly viscous fluids including
concrete and heavy oils and special applications demanding low flow rates against
high resistance.
GEAR PUMP:
This uses two meshed gears rotating in a closely fitted casing. Fluid is pumped
around the outer periphery by being trapped in the tooth spaces. It does not
travel back on the meshed part, since the teeth mesh closely in the centre. Widely
used on car engine oil pumps.
GEAR PUMP
Fig: 18
SCREW PUMP:
SCREW PUMP
Fig: 19
Screw pumps are rotary, positive displacement pumps that can have one or more
screws to transfer high or low viscosity fluids along an axis. A classic example of
screw pumps is the Archimedes screw pump that is still used in irrigation and
agricultural applications.
VALVES:
Valves are devices which regulate flow of fluids (gases, liquids, fluidized solids, or
slurries) by opening, closing, or partially obstructing various passageways. Valves
are technically pipe fittings, but are usually discussed as a separate category. In an
open valve, fluid flows in a direction from higher pressure to lower pressure.
Valves used in the plants can be categorized into:
Butterfly valve
Check valve
Control valve
Gate valve
Globe valve
BUTTERFLY VALVE:
A butterfly valve is a valve which can be used for isolating or regulating flow. The
closing mechanism takes the form of a disk. Operation is similar to that of a ball
valve, which allows for quick shut off. Butterfly valves are generally favored
because they are lower in cost to other valve designs as well as being lighter in
weight, meaning less support is required. The disc is positioned in the center of
the pipe, passing through the disc is a rod connected to an actuator on the
outside of the valve. Rotating the actuator turns the disc either parallel or
perpendicular to the flow. Unlike a ball valve, the disc is always present within the
flow; therefore a pressure drop is always induced in the flow, regardless of valve
position.
BUTTERFLY VALVE
Fig: 20
CHECK VALVE:
A check valve, a valve which normally allows fluid (liquid or gas) to flow through
it in only one direction.
Check valves are two-port valves, meaning they have two openings in the body,
one for fluid to enter and the other for fluid to leave. There are various types of
check valves used in a wide variety of applications. Check valves are often part of
common household items. Although they are available in a wide range of sizes
and costs, check valves generally are very small, simple, and/or inexpensive.
Check valves work automatically and most are not controlled by a person or any
external control; accordingly, most do not have any valve handle or stem. The
bodies (external shells) of most check valves are made of plastic or metal.
CHECK VALVE
Fig: 21
Heart valves are essentially inlet and outlet check valves for the heart ventricles,
since the ventricles act as a pump.
CONTROL VALVE:
Control valves are valves used to control conditions such as flow, pressure,
temperature, and liquid level by fully or partially opening or closing in response to
signals received from controllers that compare a "setpoint" to a "process
variable" whose value is provided by sensors that monitor changes in such
conditions.
CONTROL VALVE
Fig: 22
GATE VALVE:
A gate valve, also known as a sluice valve, is a valve that opens by lifting a round
or rectangular gate/wedge out of the path of the fluid. The distinct feature of a
gate valve is the sealing surfaces between the gate and seats are planar, so gate
valves are often used when a straight-line flow of fluid and minimum restriction is
desired. The gate faces can form a wedge shape or they can be parallel. Typical
gate valves should never be used for regulating flow, unless they are specifically
designed for that purpose. On opening the gate valve, the flow path is enlarged in
a highly nonlinear manner with respect to percent of opening. This means that
flow rate does not change evenly with stem travel. Also, a partially open gate disk
tends to vibrate from the fluid flow. Most of the flow change occurs near shutoff
with a relatively high fluid velocity causing disk and seat wear and eventual
leakage if used to regulate flow.
GATE VALVE
Fig: 23
Typical gate valves are designed to be fully opened or closed. When fully open,
the typical gate valve has no obstruction in the flow path, resulting in very low
friction loss.
Gate valves are characterized as having either a rising or a no rising stem. Rising
stems provide a visual indication of valve position because the stem is attached to
the gate such that the gate and stem rise and lower together as the valve is
operated. No rising stem valves may have a pointer threaded onto the upper end
of the stem to indicate valve position, since the gate travels up or down the stem
on the threads without raising or lowering the stem.
GLOBE VALVE:
A globe valve is a type of valve used for regulating flow in a pipeline, consisting of
a movable disk-type element and a stationary ring seat in a generally spherical
body.
GLOBE VALVE
Fig: 24
Globe valves are named for their spherical body shape with the two halves of the
body being separated by an internal baffle. This has an opening that forms a seat
onto which a movable plug can be screwed in to close (or shut) the valve. The
plug is also called a disc or disk. In globe valves, the plug is connected to a stem
which is operated by screw action in manual valves. Typically, automated valves
use sliding stems. Automated globe valves have a smooth stem rather than
threaded and are opened and closed by an actuator assembly. When a globe
valve is manually operated, the stem is turned by a hand wheel.
Globe valves are used for applications requiring throttling and frequent operation.
FURNACE:
Furnaces are used in the plant mainly for heating the fuel oil, heating of air. A
many number of furnaces are used in the plant. Some furnaces are side by side or
divided by walls.
Furnaces are of different types:
Induced draft furnace
Forced draft furnace
Mixed draft furnace
In the industry most of the furnaces were mixed draft furnace.
DESCRIPTION OF FURNACE USED:
The furnace use was mixed draft furnace.
This furnace comprises of:
Convection zone
Radiation zone
Induced draft fan
Forced draft fan
Damper
Duck
Burner
Pipelines for steam & fuel oil
AIR TO FD
AIR PREHEATING
SECTION
DAMPER
ID FAN
CONVECTION ZONE
FO STEAM
FEED IN
RADIATION ZONE
AIR
FURNACE
VALVES
FEED OUT
BURNER
DUCK
FD FAN
Fig: 25
In furnace first the air is preheated; as the temperature of air has to be increased
for lesser consumption of fuel. The air required for burning is obtained via use of
Force draft fan.
Damper is used in the chimney which controls the flow of flue gas.
Steam and fuel oil is passed which is used for heating the oil and air.
The flue gas generated is hot air so the heat of it is utilized for preheating of air.
This is done by the use of Induced draft fan as shown in the figure.
In the furnace the heating is done in two zones;
Convection zone
Radiation zone
The crude or feed is first heated in convection zone where the heating first takes
place through convection heat transfer from hot air to the oil.
Then the final heating is done in the radiation zone where the maximum heating
is done as in this mode the heat transfer is maximum.
Various valves are used which controls the flow of the fuel oil and the steam.
HEAT EXCHANGERS:
A heat exchanger is a device built for efficient heat transfer from one medium to
another. The media may be separated by a solid wall, so that they never mix, or
they may be in direct contact. They are widely used in space heating,
refrigeration, air conditioning, power plants, chemical plants, petrochemical
plants, petroleum refineries, natural gas processing, and sewage treatment.
In company mainly shell and tube heat exchangers are used.
Fig: 26
Two fluids, of different starting temperatures, flow through the heat exchanger.
One flows through the tubes (the tube side) and the other flows outside the tubes
but inside the shell (the shell side). Heat is transferred from one fluid to the other
through the tube walls, either from tube side to shell side or vice versa. The fluids
can be either liquids or gases on either the shell or the tube side. In order to
transfer heat efficiently, a large heat transfer area should be used, leading to the
use of many tubes. In this way, waste heat can be put to use. This is an efficient
way to conserve energy.
Heat exchangers with only one phase (liquid or gas) on each side can be called
one-phase or single-phase heat exchangers. Two-phase heat exchangers can be
used to heat a liquid to boil it into a gas (vapor), sometimes called boilers, or cool
a vapor to condense it into a liquid (called condensers), with the phase change
usually occurring on the shell side. Boilers in steam engine locomotives are
typically large, usually cylindrically-shaped shell-and-tube heat exchangers. In
large power plants with steam-driven turbines, shell-and-tube surface condensers
are used to condense the exhaust steam exiting the turbine into condensate
water which is recycled back to be turned into steam in the steam generator.
Among shell and tube heat exchangers the different types are:
Fig: 27
Fig: 28
Fig: 29
PIPELINES:
Pipeline transport is the transportation of goods through a pipe. Most commonly,
liquid and gases are sent, but pneumatic tubes that transport solid capsules using
compressed air are also used.As for gases and liquids, any chemically stable
substance can be sent through a pipeline. Therefore sewage, slurry, water, or
even beer pipelines exist; but arguably the most valuable are those transporting
fuels: oil (oleoduct), natural gas (gas grid) and biofuels.
Water
Crude oil
Hydrogen gas
Finished product
AN OVERVIEW OF PIPELINES
Fig: 30
CONTROL SYSTEMS:
In the plant two types of control system is mainly used:
DCS is a very broad term used in a variety of industries, to monitor and control
distributed equipment.
OVERVIEW OF DCS
ARRAGEMENTS
Fig: 31
PLC
ARRANGEMENTS
Fig: 32
CONCLUSION:
CONCLUSION:
FCCU is the most profitable unit in refinery and CRU is the next more
profitable.
Full plant is running on DCS system but some controls are also done by PLC
systems.
The main profit of IOCL Haldia refinery comes from crystalline wax.
Haldia refinery does not produces lube oil they produce the LOB( lube oil
base stock)
DECLARATION
It was a learning experience for us. Not only did we learn about
the details of the refining processes but also acquired
knowledge about the proper mechanical operations of various
equipments. The training provided us with the insight of how a
refinery operates with the proper co-ordination between the
management and the grass root level.
BIJIT BISWAS
KOUSHIKA SARKAR
SUBHASANKAR SAMANTA
SUDHANYA CHOUDHURI