-:ATMOSPHERIC DISTILLATION UNIT (AU):-

AU-I : Processes crude that comes from South Gujarat, North Gujarat and
Bombay high.
AU-II : Processes crude of North Gujarat.
AU-III
AU-IV : Processes Nigerian crude
AU-V : Processes high sulfur containing crude imported from Nigeria and
Saudi Arabia.

Distillation is a method of separating the components of a solution, which depends

upon the distribution of the substances between a gas and a liquid phase, applied to
cases where all components are present in both phases.

ATMOSPHERIC DISTILLATION UNIT –I/II:-

Atmospheric Distillation Unit No.1 was designed to process 1.0 MMTPA of

Ankleshwar Crude. It was commissioned on 15.10.1965.

 At various stages AU-1 was revamped to increase its processing capacity to 1.4
MMTPA.
 Atmospheric Unit AU-1 consists of Electrostatic Desalter, Preflash tower K-1,
Main Fractionator K-2, Naphtha Stabiliser K-5 and Rerunning Section (K-8 &
K-9).

FUNCTION OF PLANT

After revamp AU-1 can process ANK: NG crude in 70:30 ratio.

Various products from the units are :

i. LPG
ii. IBP-70 Deg.C cut - Naphtha component.
iii. Light Charge Stock (70-90 Deg.C cut) - Feed for Aromatic run in CRU.
iv. 90-140 Deg.C cut - Feed for MS operation in CRU.
v. IPCL Naphtha (110-140 Deg.C cut) - Feed stock for Xylene Plant.

vi. ATF
vii. SK or LABFS - Feed Stock for IPCL or Heavy Kero Feed for LARO production
in PDF.
viii. HSD normal or Navy HSD or Army HSD.
ix. RCO
NOTATIONS:

COLUMN SERVICE PRESSURE (kg/cm2)

K-1 Crude Pre-topping column 3.5
K-2 Main Fractionating column 1.6
K-3 (I) ATF Stripper 9.5
K-3 (II) Diesel Stripper -
K-5 Naphtha -
K-7 Naphtha Splitter 4.0
K-8 Naphtha Splitter 1.3
K-9 Naphtha Splitter 1.6
K-10 Naphtha Splitter -

PROCESS DESCRIPTION:-

CRUDE STORAGE AND SETTLING:-

Adequate settling time, 12 hours or more after completion of receipt is required

to be given for each tank to settle down water/sludge. The water is thoroughly
drained before feeding to the unit. The sludge from the tank is drained to melting
pit.

A crude tank prepared as above, is first fed at slow rate by crack opening of
outlet valve (bleeding), along with the already feeding tank. After minimum of 4
hours bleeding, this may be made a complete feed tank. This procedure is adopted
to avoid unit upsets due to possible sudden influx of water or abrupt feeding of
different quality crude from the fresh tank. Feeding from the crude tank to the unit
crude feed pump may be either by gravity, as in the case of low feed requirement, or
via crude booster pump as in the case of higher throughput requirement.

FEED PREHEATING:-

Through the crude booster pump provided at GR crude control, crude enters the
unit. Demulsifier is injected at down stream of the crude battery limit valve on
crude line to pump suction. Slop oil, flushing oil and circulation line hook up is
provided on crude line to pump suction.

DESALTER OPERATION:-

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. The pressure drop around mixing valve is maintained around 1.2
to 1.4.
 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 desolved 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 30%. The exact interface level for efficient desalting will depend
upon the salt content and appearance of effluent water.

To physically check the interface level, 5 Nos. of try lines are provided and
sample from these try lines is checked through a sample cooler. As a general
guideline, interphase level should be maintained around 3rd-try line.

A temperature indicator is provided on Desalter outlet line.

Two nos. of safety valves PSV-1351&PSV1352 set at 19.0 Kg/cm2g are

provided on Desalter which are located near K-1. In case of excess pressure, these
safety valves release pressure to column K-1 bellow tray No. 1.

Due to low temperature of crude from Desalter close watch is to be kept to

avoid reduction in K-1 bottom temperature and subsequently lighter material going
to column K-2. Out of these two safety valves only one shall remain on line.

Two desludging pumps PA-002 A/B have been provided for continuous
desludging. One pump runs at a time. Desludging pump takes suction from
Desalter bottom and pumps back Desalter effluent in the Desalter through
desludging header.

DISTILLATION SECTION :

Crude is preheated upto 130 to 140 Deg.C (desalting temperature) with ATF, HSD
(Product + CR), Kerosene (Product + CR) and RCO. Desalting water, preheated by
heat exchange with Desalter effluent is injected into the crude at Desalter inlet or
alternatively at T1 respectively. The desalted crude picks up additional heat by
further heat exchange with diesel CR and RCO, before it enters the
preflash/pretopping column K-1.

Pretopping Column is meant for removal of lighter ends from the crude and
has 28 trays. (1 to 9 are 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-1101 A/B/C set at 3.5 Kg/cm2 (g)
pressure releasing excess pressure to flare.

The column is operated at 2.90 Kg/cm2 (g) and 240 Deg.C bottom temp.

Light naphtha boiling upto about 130 Deg.C is recovered as overhead product
from this column, which also contains lighter hydrocarbons like gas and LPG.
 To remove LPG components from bottom products of K-1, stripping steam of 5
atm. pressure is introduced at the rate of 300-500 Kg/Hr. which does reflect in E-2
gasoline whether c3/c4 components are present or not.

The overhead vapours 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 vapour line to avoid

corrosion in condensers and reflux drum.

Ammonia is injected into vapour lines of K-1/K-2 to neutralize residual

hydrochloric acid by converting it into NH4CL and to maintain pH of E-2 boot
water in the range of 6 to 6.5, because effectiveness of corrosion inhibitor is more
in this range of pH.

The preflash column has 9 trays below and 19 trays above the flash zone.
Reboil heat is supplied to column K-1 by one cell of the twin cell heater F- 1.

The overhead vapours are condensed in condenser T-11 A/B/C and collected in
E-1. Due to presence of non-condensable in crude a controller 1PC-1301 is
provided on the vessel E-1. This control valve release excess pressure, either to gas
away or to flare, to maintain E-1 pressure at 2.2 Kg/cm2 (g).

Water coming to E-1 is drained through differential level controller. High

interface level alarm and low interface level alarm is provided at E-1.

A part of the E-1 gasoline is sent to the stabilizer K-5 while the rest is returned
to column K-1 as reflux. The bottom product from K-1 is further heated and
vaporized in furnace F-1 (K-2 side) and is introduced into the flash zone of main
fractionator K-2. Provision is there to route E-1 gasoline to GOP, GN or MS.

Six stripping trays are provided below the flash zone where the reduced crude is
stripped with steam to remove the lighter constituents. The stripping section
vapours together with the vapourised portion of the feed are fractionated on the
trays above the flash zone to yield liquid side products and vapour over head
stream.

HSD is withdrawn as the first side stream at 200-370 Deg.C from 14th tray
along with HSD CR. The product stream enters the stripper K-3. The HSD and
HSD CR are cooled by heat exchange with crude before it is routed to
storage/returned to main fractionator respectively.

Kerosene is withdrawn at 160-270 Deg.C from 26th tray. They are cooled by
heat exchange with crude after which the circulating reflux is returned to K-2 and
the product is cooled and sent to storage.

ATF is withdrawn at 140-240 Deg.C from 34th tray and after exchanging heat
with crude is further cooled and sent to storage. The ATF stripper has been filled
with hypack packing. The ATF from K-2 enters above this packing. Stripping steam
is introduced at the bottom of the section through 1FC-1463 and the stripped off
vapours alongwith steam return to column K-2 above 34th tray. Stripping steam to
K-3 is adjusted to maintain ATF flash point around 41 Deg.C. On average 15 to 20
 Kg/hr. steam is required per m3of ATF withdrawal per hour. On ATF ex-K3, a
temperature indicator 1TI-1472 is provided.

The overhead naphtha vapours are condensed in the condenser T-12 A/B/C/D
and collected in E-2.T-12D one set of condenser is installed for emergency service
during cleaning of other set without loosing throughput. E-2 gasoline partly along
with E-2 gasoline (AU-2) is sent to V-1 and the balance is returned to K-2 as reflux.

The stripped RCO from K-2 bottom exchanges heat with crude and are then
cooled in coolers before sending to storage.

FURNACE: Furnace F-1 has two separate radiation K-1 side and K-2 side and
common convection zone. K-1 side cell supplies reboil heat to column K-1 and K-
2 side cells and convection section provides heat for vapourisation of distillates in
K-2 feed. To improve furnace efficiency F-1 has been provided with air preheaters
(APH), FD fan and ID fan.

Unstabilised gasoline (E-1 gasoline) is sent to stabilizer K-5 along with CRU
drag stream. It is preheated by successive heat exchanger with RCO and K-5
bottom. The overhead from K-5 is condensed and a part is withdrawn as LPG and
rest is sent to column as reflux. The reboil heat to K-5 is supplied by circulating
part of K-5 through furnace F-2. Stabilized naphtha from K-5 i.e. K-5 Bottom,
along with K-5 bottom from AU-2 after preheating stabilizer feed is routed to K-8.

NAPHTHA RERUN SECTION (K-8, K-9 and K-10 circuit)

The feed to K-8 consists of the following streams:

i. E-2 gasoline from column K-2 (AU1)

ii. K-5 bottom naphtha & E2 gasoline ex AU-3.
iii. Bombay high naphtha from OM&S.
iv. E-2 gasoline from column K2 (AU2).
v. K5 Bottoms (AU1+AU2) after feed preheating K-5 feed.

The quantity of BH Naphtha is varied so as to maintain V1 level. The first four

streams are combined in V1and preheated in E201A/B & T2E (Bottom) by heat
exchanger with K-9 bottoms. Provision has been given to take E-2 gasoline via
steam heater E-302 directly as K-8/K9 feed. The preheated naphtha is heated in T-
2E with IPCL Naphtha from K-10, and alongwith K-5 bottom (AU1+AU2). It is
further heated up in E202A/B before entering in K8. Furnace F-4 and E-303
provides necessary reboil heat duty for column K-8. The IBP-70 Deg.C cut Naphtha
is recovered as overhead vapours and condensed in T-15 A/B and T-16A/B and
collected in E-7 and E-8. A part of liquid from E-7 and E-8 is sent as run down to
GHP / MS / GN / GOP while the rest is sent to K-8 as reflux.

The bottom product from K-8 is directly sent to column K-9 which is reboiled
by furnace F-3 and F-5. The 70-90 Deg.C cut Naphtha is recovered as overhead
vapours and condensed in the condensers T-17 A/B/C and is collected in E-9.

A part from E-9 is sent to column as reflux and rest is sent to rundown to Light
Charge stock / GN / MS. K9 bottom is sent as rundown to MS / GN/ CRU feed.110-
140 Deg.C Naphtha (IPCL Naphtha) is withdrawn as a side stream and sent to IPCL
 Naphtha stripper K-10. Reboil duty for K-10 is provided by T-10 in which MP
steam is used as heating medium.

IPCL Naphtha is withdrawn from T-10. IPCL Naphtha exchanges heat with K-8
feed in T-2E(Bottom) and is cooled in cooler T-26. IPCL Naphtha after cooling is
sent to CRU/MS. N-Heptane feed cut is withdrawn from 44th tray of K-9 by pump
H-25 and cooled in cooler T-20E. K-9 bottom stream preheats K-8 feed in E-
201A/B and is cooled in T- 27 and E-203 A/B before it is routed to R/D.

LPG CAUSTIC WASH FACILITY

Presence of mercaptanes and H2S renders LPG corrosive. In AU-1 LPG copper
corrosion is in the range of lb to 2a whereas in AU-2 LPG copper corrosion is
around 4. To improve the LPG quality (copper corrosion 1a or less) LPG caustic
wash facility is provided in AU-1 to treat AU 1/2 LPG.
LPG gets separated in caustic wash vessel and comes out from the top where as
caustic gets settled and drained.
In the caustic wash vessel (LPG extractor) continuous fresh caustic injection
(strength around 10 %) with the help of P-40 A/B is done.Spent caustic is
continuously drained from the extractor Part of the spent caustic ifrom the bottom
of extractor is recirculated in the extractor with the help of P-111B/P115.2 Nos. of
safety valves set at 18 Kg/cm2 (g) releasing excess pressure to flare are provided on
LPG caustic wash vessel.

NAPHTHA CAUSTIC AND WATER WASH FACILITIES

Presence of mercaptanes and H2S renders naphtha corrosive. To improve the

naphtha (copper corrosion 1a or less) naphtha caustic and water wash facilities are
provided for K-8 top of AU-1 and K7 top of AU-2.

K-8 top naphtha is routed to naphtha caustic wash vessel and caustic is
circulated by pump P-113A/B. Naphtha gets separated in caustic wash vessel and
comes out from the top where as caustic gets settled. Spent caustic is drained.

CHEMICAL INJECTION SYSTEM

Chemical injection system is provided in the unit to achieve the following :

a. To facilitate demulsification in Desalter, demulsifier is added.

b. To protect K-1, K-2 and K-5 overhead systems against corrosion, ammonia water,
Ahuralan and ammonical caustic solution is added.

DEMULSIFIER

A demulsifying agent is injected into the crude oil at the crude pumps common
suction header in the unit at the rate of 3 to 6ppm on crude throughput. Demulsifier
helps in faster demulsification inside the Desalter, thereby helping in faster removal
of water injected for dissolving salt. Demulsifier is injected with the help of pump
 which takes suction from demulsifier tank. A rotameter isprovided for checking
pumping rate. Injection rate of demulsifier is adjusted by varying the pump stroke.

CAUSTIC INJECTION

Calcium and Magnesium Chloride present in crude releases HCL due to

hydrolyses on heating which 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 water soluable NaCl. The caustic dosing is done at
a fixed rate of 40ppm on N/G crude throughput and is injected at crude outlet line
from Desalter.

Caustic is received from OM&S in the form of caustic lye of 48% strength.
Dilute ammonical caustic solution 8% is prepared by adding DM water and
bubbling ammonia. Caustic is injected in Desalter outlet line with the help of
injection pumps at the rate of 40ppm based on N/G crude quantity. Ammonical
caustic is prepared in Tank-E and transferred to Tank C/D via P-40A pump.

AMMONIA SOLUTION INJECTION

Ammonia is injected into vapour lines of K-1/K-2 to :

i. Neutralize residual hydrochloric acid by converting it into NH4 CL.

ii. Maintain pH of E1/ E-2 water in the range of 6 to 6.5, because effectiveness of
corrosion inhibitor is more in this range of pH.

Ammonia is received in the unit in 40 Kg cylinders. Ammoniacal water solution

is prepared by bubbling gaseous ammonia from cylinder, through fresh water in
ammonia tank. There are three dosing pumps available (one to be used at a time)
for injection, viz. H-5/5A/5B. Ammonia is injected into K1/K-2 vapour line so that
E1/E-2 water pH remains in the range of 6 to 6.5.

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 is done into the top sections of K-1, K-2, K-5 separately, at
the rate of 5ppm of production of overhead material in the respective columns.

ASA INJECTION FACILITY

ATF has conductivity in the range of 2 to 5 PS/M (Pico semen per meter).
Owing to its low conductivity. ATF has a tendency to accumulating electrostatic
charges which are generated during transfer of ATF. This may lead to serious fire
hazards due to sudden discharge of electrostatic charges with a spark.
 Antistatic additive is added to increase conductivity and reduce the development
of dangerous electrostatic charges. A conductivity of min. 50 PS/M is required, but
sufficient additive should be introduced to raise the conductivity around 200 to 300
PS/M in order to allow for subsequent depletion over long period of time. (It has
been observed that within 2 days ATF conductivity falls by 50 to 70 PS/M). Max.
permissible conductivity is 450 PS/M.

TROUBLE SHOOTING:-

PROBLEM PROBABLE CAUSES OF REMEDY

PROBLEM
1. Too much salt Mixing valve pressure drop is Increase mixing valve pressure
remains in the too low. drop.
treated oil.
Insufficient amount of wash Increase Fresh water flow rate.
water being
Operating temp. too low. Increased temp. of untreated oil

2. There is too Mixing valve pressure drop is
much water in too high
treated oil.
Water injections rate too
high.
Untreated crude has very
high BS&W content
insufficient oil and water
separation is occurring.
Reduce mixing valve pressure
drop.
Reduce water injection rate.
Sample crude for BS&W; a
change in fresh water injection or
mixing valve pressure drop may
help

Voltage at the electrode Check electrical system for

assembly is too low. operating problem.

Not enough demulsifier Increase demulsifier chemical

chemical is being added to injection rate/or change type of
untreated crude or type of demulsifier chemical.
demulsifier should be
changed.

Oil/Water interface level too Adjust controller set point as

low necessary

3. Dirty effluent Incorrect amount or wrong Adjust injection rate of

water is exiting type demulsifier chemical is Demulsifier chem. And / or
at the effluent being added to untreated oil. change type of demulsifier
water line. chemical.

Oil temp. is too low for good Check temp. and increase as
operation of plant. necessary.

Mixing valve pressure drop Reduce mixing valve pressure

too high or process water drop and/or process water
PROBLEM PROBABLE CAUSES OF REMEDY
PROBLEM
injection rate too high injection rate.

Set point at level controller Check controller set point and

may be improperly adjusted valve action. Adjust if necessary.
or the valve on the effluent
water outlet may be stuck up

4. Voltmeter Vessel operating temps too Check vessel temp. adjust temp.
Readings vary high or backpressure of oil if necessary.
widely and insufficient.
continuously. Check action of backpressure
valve.

Incorrect operation of Check controller for correct

oil/water inter face sensor, operation. Check sensor
controller calibration if necessary

Incorrect amount or wrong Adjust injection rate of

type demulsifier chemical is demulsifier chemical and/or
being added to untreated change type of demulsifier
crude. chemical.

Mixing valve pressure drop Reduce pressure drop at mixing

too high valve.

An insulator inside the vessel Take the vessel out of service.

has failed. When entry is permitted, enter
vessel and determine which
insulator has failed and replace it.

Shutdown system. Inspect vessel

Energized electrode has interior and locate point at which
become grounded. electrode is grounded.
Ungrounded the electrodes.
 -:VACUUM DISTILLATION UNIT (VDU):-

INTRODUCTION:-
The vacuum Distillation Unit, also called Feed preparation Unit (FPU) and is
designed to produce Diesel, Light Vacuum Gas Oil (LVGO), Heavy Vacuum Oil
(HVGO), slop & vacuum Residue (VR).

The unit is called Feed Preparation Unit because it produces & supplies feed to
Hydrocracker Unit i.e. Light Vacuum Gas Oil & Heavy Vacuum Gas Oil.

FPU uses Reduced Crude Oil as feed which is supplied to it directly from
storage tanks and/or from existing Atmospheric Distillation Units
(AU1/AUII/AUIII) processing North Gujarat Crude. Provision is also kept to
receive RCO from AU (IV) & AU (V).

CAPACITY /THROUGHPUT:-

Design:
The design feed and product quantities are given below (approx. only):

MATERIAL BALANCE OF VDU:

IMP HS RCO DESIGN DESIGN

MTPD YIELD %

FEED (370+ TBP) 3600

SLOP OIL MINIMAL
HHSD (370- TBP) 125 3.5
LVGO (370-530 TBP) 686 19.0
HVGO (370-530 TBP) 763 721.2
SLOP CUT (530-550 TBP) 245 6.8
VR (550+ TBP) 1781 49.5
3600 100.00
PROCESS DESCRIPTION:

For convenience of description, Feed Preparation Unit (FPU) is divided into following
main sections :

1. RCO surge drum and preheat section

2. Vacuum Furnace & APH

3. Vacuum Column

4. Product Routing and Cooling

5. Vacuum Column Overhead Section

6. Steam Generation System

RCO Surge Drum and Preheat Section

RCO is received in feed surge drum 03-VV-001 located in unit from

Atmospheric Distillation unit AUI/ AUII/ AUIII/ AUV & AUIV) and / or from
storage tanks located in offsites which is a horizontal tank on ground. RCO from
Atmospheric Units is received at 1100C; called Hot Feed to 03-VV-001 from
Atmospheric Units. Normally RCO from units is directly received at around
1100C.RCO from storage tanks is available at 800C, called Cold Feed.

Under normal operation, 80% (Actually 35 to 45%) of RCO through put

requirement will be met from operating Atmospheric Units while balance 20%
RCO will be received from storage tanks. However, provision has been kept to
process entire feed RCO from storage tanks in case of non availability of the same
from Atmospheric Units.

The feed surge drum pressure is maintained at around 240 kgs/cm 2 through a
split range pressure controller 03-PIC-1101. 3-PV-1102 admits fuel gas to surge
drum while 03-PV-1101 releases fuel gas to flare in case the pressure falls or rises
below or above set valve. A LP steam coil (with automatic condensate releases) is
provided to maintain surge drum temp. above 80°C.

RCO from the surge drums is pumped by RCO feed pumps, 03-PA-001 A/B
(one pump remains standby) through a series of feed/product heat exchangers
before heating it in vacuum heater to desired temperature.

RCO is successively heated while passing further through a series of exchangers

in sequence.
Vacuum Furnace

Reduced crude from 03EE05 & EE102 at 310 Deg. C (Actual 288 to 293°C) is
joined by Vacuum slop distillate recycle stream at 350 Deg. C. The combined
stream then enters the eight passes of Vacuum furnace 03FF001. Pressure gauges
are at inlet of each pass and at the external cross over of oil coils from convections
to radiation section. Temperature indications are also provided on the external cross
over. To increase the velocity of oil in the coils and to avoid coking, facility to
inject MP steam is provided in all the passes. The partially vaporized stock leaving
the furnace is transferred through a 42" line into the flash zone of column.

In addition to hydrocarbon coil, the convection section also has LP steam super
heater coil. LP steam is superheated in eight passes in the convection section before
entering the vacuum column as stripping steam. BFW injection is done for
desuperheating the steam at coil outlet. Soot blowers (2 rows of 10 soot blowers
each) are provided in the convection of the furnace to remove the deposits on the
tubes.

Vacuum Column

The vacuum column has 3 different diameters. Top section is of 7400 mm dia,
middle is of 8400 mm dia and bottom section of 5250 mm dia. It is 43950 mm tall.
The tower is made of carbon steel with 3 mm thick lining of SS 316L material on
inner walls. All draw off trays are chimney type and are of SS-316L. The column is
provided with five sections of packed beds. Immediately above the flash zone a
wash section is provided. This consists of one set of packing. A bed of mellapak
structured packing is provided. Below the packing withdrawal tray is located. The
structured packing above this is washed by a circulating reflux stream withdrawn
from HHVGO draw off tray. The circulating reflux rate has been fixed so as to
ensure a liquid flow rate of about 1 gpm/ft2 of tower cross sectional area in order to
achieve proper washing.

In addition to above, in the flash zone of the column a circumferential baffle

above the feed inlet and a vapor de entrainment baffle above the stripping section
have been provided to minimize the entrainment of heavy hydrocarbon liquid
droplets. A bed of structured mellapak packing is provided on HHVGO draw off
section, which is washed by HVGO, internal reflux. Two spray distributors (for
HSD PA, HSD IR) and four gravity distributors are provided over packed beds for
proper distribution of reflux stream. IMTP random packing is provided on HVGO
draw off section. The height of the packing is governed by heat withdrawal
requirement by HVGO circulating reflux. Similar packing is provided for LVGO
and Diesel withdrawal section also.

LVGO section is provided with two packed beds. The height of the lower bed of
IMTP random packing is governed by heat transfer requirement for LVGO
circulating reflux. Another bed of mellapak structured packing is provided just
below the Diesel withdrawal tray to ensure proper separation of LVGO and
Diesel components. The Diesel section is provided with a IMTP packing bed,
the height of which is governed by heat transfer requirements for Diesel
 Circulating Reflux. Spray nozzles are provided above each packed bed for
proper distribution of reflux stream. Height of the various packing along with
duty requirement for rated capacity is listed below.

Stainless steel demister pads are provided below the top vapor outlet nozzle to
arrest carryover of Diesel as mist along with steam and other non-condensable. 5
Nos. of valve trays of SS 316 L material are provided below the feed nozzle, to strip
off the distillate from the liquid fraction of the feed. Stripping steam is provided
below the 1st tray to affect the stripping.

The vapour liquid mixture from the transfer line flashes further as it enters the
flash zone in the vacuum column. Hot vapours rise up in the column. Flash zone
temperature is 3850C for Case-1 feed and 380°C for Case-2 feed. Flash zone
pressure is maintained at 0.878 Kg/cm² (93 mm Hg) through column top pressure
control system. The column top temperature is controlled by adjusting the Diesel
Pump Around flow rate. Top pressure and temperature of the column are maintained
at around -0.914 Kg/cm2 and 85°C for Case-1 & 95OC for case- II respectively.

Pressure safety valves are provided at the top of the column to protect the
column against the over pressurization. Safety valve discharges are connected to
flare. The liquid called vacuum Residue (VR) is collected at the column bottom,
quenched with comparatively cold VR (at 290°C to maintain the bottom
temperature around 360°C, so that thermal cracking & subsequent coke formation
is avoided in case of longer residence time.

A 14" steam header supplies superheated low pressure steam at 330°C to the
column bottom, below the 1st valve tray. A 2" Nitrogen connections is provided for
start up/ shutdown inertising of the column.

Product Routing And Cooling

Vacuum Residue

Vacuum bottoms are pumped out by Vacuum Residue pump 03-PA-006 A/B.
The pump has a rated capacity of 300 M3/hr. and develops a discharge pressure of
27.5 kg/cm2g. The discharge of the pump goes to Vacuum Residue/RCO
exchangers 03-EE-004 C/D/E/F where it exchangers heat with incoming RCO. A
part of the Vacuum Residue from the outlet of 03-EE-004 C can be sent to IFO pool
(VR surge drum). Flow of this stream is adjusted manually with the help of a globe
valve.

Another part of Vacuum Residue (VR) goes back to column 03-CC001 as

quench. The quench flow at 290°C is regulated through 03-FIC-1403. At rated
capacity quench flow 14M3/hr. 25 M3/hr. requirement is about 25.6 MT/hr &
5MT/hr for Case-1 & Case-2 respectively. Balance stream of VR goes to exchanger
03-EE-001 A/B/C/D, where it is further cooled to around 200°C by exchanging heat
with RCO.
 Routing of Vacuum Residue from outlet of exchanger 03-EE-001 A/B/C/D are
as follows:

One portion of VR at about 200°C from outlet of exchanger 03-EE-001 A is sent

to VBU. Balance of the VR is further cooled to 120°C with the help of tempered
water cooler 03-EE-012 A/B/C. Vacuum Residue from the outlet of Tempered
Water Cooler can be sent either to LSHS storage, IFO pool or to VBU as cold feed
as per requirement.

Slop Distillate

Vacuum Slop Distillate is drawn from lowest chimney tray and pumped by slop
Distillate pumps 03-PA-18 A/B. Each pump is having a normal capacity of 36
M3/hr with a discharge pressure of 20.5 kg/cm2g. It exchanges heat with RCO and
cooled down to around 355°C and 312°C at the outlet of 03-EE-102 and 03-EE-05
respectively.

Slop Distillate Product from 03EE05 to 03-LIC-1401 goes through exchangers

03-EE-007 where it heats up Boiler Feed water, and in the process gets cooled
down to around 281°C. Slop distillate ex 03-EE-007 is further cooled to around
109°C in Tempered Water cooler 03-EE-011 A/B/C from where it can be sent to
LSHS Storage/IFO pool or slop tanks.

Heavy Heavy Vacuum Gas Oil(HHVGO)

HHVGO product and Internal Reflux is withdrawal from the fourth chimney
tray from top. HHVGO from column is pumped by 03PA17A/B at draw off
temperature of 3600C. HHVGO IR steam goes to below 4th tray for temperature
control and mars transfer. A minimum flow of HHVGO IR to be kept fixed to avoid
any coke formation.
HHVGO product stream exchanges heat with RCO first in 03EE105 (s/s) and
goes through 03LIC1407 before divided into two streams. One goes to HVGO
outlet of 03EE103. Other stream goes to 03EE104 exchanges heat with RCO and
coals sawn to 180 deg C. thereafter the HHVGO product can be routed to FCC
(Controlled by 03FC1902) or to VGO rundown depending upon the specifications
and requirement.

Heavy Vacuum Gas Oil (HVGO)

HVGO Product, Internal Reflux and Pump around streams are drawn from
second chimney tray by pump 03-PA-004 A/B. Withdrawal Temperature is 310°C.
Normal capacity of the pump is 546 M 3/hr. and delivers at a pressured of 11.8
kg/cm2g.

A part of HVGO from discharge of 03-PA-004 A/B is going back to column 03-
CC-001 as HVGO internal Reflux on the top of mellapak packing provided in the
HHVGO section of the column. Purpose of this stream is to wash down the heavier
hydrocarbons which may affect the quality of VGO feed. The Internal Reflux is
distributed on entire packing area through gravity distribution. Another part of
HVGO from discharge of pump 03-PA-004 A/B goes to exchanger 03-EE-003
A/B/C/D where it exchangers heat with RCO. HVGO from outlet of exchanger 03-
EE-003 A/B/C/D at around 264°C (Actually 300T) goes to 03EE101A/B & then at
2400C back to column 03-CC-001 as HVGO Pump Around and gets distributed on
top of IMTP packing of HVGO section through a gravity distributor. Duplex filters
are provided to arrest solid particles to avoid blocking of nozzles. Under normal
operating conditions with rated plant capacity this flow should be maintained
around 250 M3/Hr. (Actually 290 to 320 M3/hr.)
Balance stream of HVGO drawn under HVGO draw-off goes to
03EE103ABCD. This stream along with part of HHVGO goes to LP stream
generators, 03-EE-008 A/B. HVGO product stream heat is partly utilized for
generating LP Stream. Flow of HVGO is splitted so that it flows in parallel through
03-EE-008 A & 03-EE-008B. HVGO ex 03H0V1601 at around 212°C joins the
HVGO stream coming from level controller 03LC1402. Mixed stream (mixing with
LVGO) is the feed for the Hydrocracker Unit and called as Vacuum Gas oil (VGO).
Under normal operating conditions, a part of the vacuum gas oil. (Called as hot
feed) is directly sent to Hydrocarbon Unit. Rest of Vacuum Gas oil goes to
Tempered water Cooler 03-EE-010 A/B. where VGO is cooled down to 86°C.

Light Vacuum Gas Oil (LVGO)

Light Vacuum Gas oil (LVGO) is drawn from second chimney tray from top at
around 258.8/259.1°C to 235°C through LVGO Product plus Pump Around pumps
03-PA-003 A/B. Pumps normal capacity is 327 M3/hr. and discharge pressure is
11.7 kg/cm2g. A part of 03-PA-003 A/B discharge is sent back to column with
HVGO Pump Around as LVGO internal reflux on the top of HVGO IMTP packing
to facilitate better separation between LVGO and HVGO components. Balance
portion of LVGO (Product + Pump around) goes to exchanger 03-EE-002 A/B
where its heat content is partially utilized to preheat RCO feed. LVGO gets cooled
to around 1950C.

A part of LVGO from the out let of 03-EE-002 A/B is returned back to column
on the top of IMTP packing provided in the LVGO section. This is distributed
through a gravity distributor over the entire cross section of the packing. A duplex
type filter 03-GN-003 A/B is provided on LVGO Pump Around line to arrest solid
particles which may otherwise block the distributor holes, crating uneven
distribution of LVGO Pump Around over the packing. Another stream is used to
generate LP steam in 03EE-107. After that it gets cooled in 03EE108 cooler and
mixes with VGO at the outlet of 03EE10A/B. The mixed goes as cold VGO to
storage at around 86OC.

Heavy Diesel

Diesel Product, Internal Reflux and Pump Around stream is withdrawn from the
top chimney tray at 149to 1600C for Case-1 & Case-2 cut feed respectively. Pumps
03-PA-001 A/B are provided for withdrawal of Diesel Product + Pump around
Stream. Pump 03-PA-003 B has connections for both LVGO, and Diesel services.
Required Diesel withdrawal rate is around 215 M3/hr
 Pump 03-PA-002 A/B developed a discharge pressure of 13.0 Kg/cm 2g at
normal pump capacity. A part of 03-PA-002 A/B discharge is going back to column
on top off LVGO packing as Diesel internal Reflux.

Filter 03-GN-002 is provided on Diesel IR line for arresting the solid particles
to avoid blocking of distributor nozzles. Flow rate of Diesel IR is maintained at
around 36 M3/hr. at normal plant capacity rest of Diesel stream (product + PA) goes
to 03-EA-001 where it is cooled to around 60°C in Air Fin Cooler. A part of the
Diesel from the outlet of 03-EA-002 goes to 03EE106A/B cooler, gets cooled to
48OC and goes back to column as Diesel Pump Around . Diesel Pump Around flow
requirement for normal plant capacity is about 145 M 3/hr. A filter 03-GN-001 is
provided on the pump around line for preventing solids from blocking the
distributor nozzle. Balance amount of Diesel goes as Diesel Product and cooled
further to 49°C by means of cooling water in the cooler 03-EE-009. Diesel Product
flow is sent either to HSD storage tank or to TPS as fuel.

All the products viz. Vacuum oil (VGO), slop distillate, vacuum Residue and
Diesel oil can be routed to slop or LSHS tank.

Chemical Injection System

Organic Acids are formed at high processing temperatures in FPU column. Some sulfur
compounds also cause corrosion to equipment. H2S is one such main component.
Corrosion in column overhead system and equipment is caused by Chloride salts
remaining in RCO. These chloride salts get hydrolyzed into HCL which attach the
metal of overhead system.

Ammonia Injection

Ammonia solution is injected into Vacuum column overhead vapour line to react with
HCL to fix it as NH3 NH4C1 and NH3 is liberated as Free Ammonia in the process. If
sour water ex hot well is maintained at a pH of 6.5 + 0.2 corrosion in overhead system
is at minimum.

Ahuralan Injection

Ahuralon solution injected in the vacuum column overhead lines forms a thin
protective coating of Ahuralon on the inner surface of overhead condenser. This thin
coating of Ahuralon prevents internals of equipment from getting corroded by
maintaining a corrosion resistant film between metal surfaces and streams.
 -:FLUIDISED CATALYTIC CRACKING UNIT (FCCU):-

INTRODUCTION

During 80’s with increased processing of the North Gujarat and Bombay High
Crude’s, the production of LSHS had gone up. This increased production of LSHS
should have been suitably disposed off to enable the refinery to operate at its
maximum throughput for meeting requirements of the petroleum products.

LSHS produced at Gujarat Refinery is supplied to following agencies:

1 Various Thermal Power Plants
2 Fertilizer Plants as Feed Stock /Fuel.
3 Other local customers in and around Gujarat as a Fuel.

This LSHS, which is presently being supplied as Fuel for burning, has a good
potential of being refined into high priced distillates, which are in great deficit in
our country. The steep increase in the prices of Crude Oil and Petroleum Products
in the past few years and Government’s Policy of conservation of Petroleum energy
has changed the situation totally and it became necessary to review the utilization of
LSHS more economically and profitably.

Based on the above consideration, the various alternatives of Secondary

Processing Schemes were examined and it was decided to install Fluid Catalytic
Cracking Unit (FCC) at Gujarat Refinery.

DEVELOPMENT OF PROCESS:-

Cracking is a phenomenon by which large oil molecules are decomposed into

small lower boiling molecules. At the time certain of these molecules, which are
reactive, combine with one another to give even larger molecules than those present
in the original stock. The more stable molecules leave the system as cracked
gasoline and reactive ones polymerize forming fuel oil and even coke. Although
primary objective in development of the cracking process had been to get more and
more of gasoline, all other oils having boiling ranges intermediate between fuel oil
and gasoline is also produced.
The originally developed process of cracking was “Thermal Cracking”. Use of
catalyst for cracking was first investigated by HOUDRY in 1927.
Catalytic cracking has many advantages over Thermal cracking viz.
1. Catalytic cracking gives more stable products.
2. For corresponding yield and quality of gasoline, catalytic cracking
unit operates under less severe conditions.
3. Catalytic cracking gives high-octane gasoline (viz.91-94 octane).
4. It yields less gas viz. Methane, Ethane and Ethylene.
 BATCH PROCESS:

The first Commercial Catalytic Cracking Unit was put into operation in 1936. It
was a Fixed-bed Catalytic Cracking Unit. It consists of a series of chamber /
reactors, wherein one of them is on-stream, the others will be in the process of
cleaning, regeneration etc. This type of process has a disadvantage of being an
intermittent process having a high initial investment and operating cost.

CONTINUOUS PROCESS:

The advantages of continuous process led to the development of the idea of a

moving bed catalyst. Examples of this type are “Thermofor Cracking”; “Thermofor
Cat Cracking” and “Houndry Airlift” processes. In the Thermofor Cat cracking, the
Palletized Catalyst was conveyed between the Reactor and regenerator by means of
Bucket Elevators. Higher investment by capacity limitations of Elevators/Air lift
systems together with other Engineering and process difficulties led to the
development of latest concept in moving bed catalytic cracking i.e. Fluidized
Catalytic Cracking.

FLUIDIZED CATALYTIC CRACKING

The radical development was made by Standard Oil Co., New Jersey, M.W.Kellogg
and UOP in early 1940’s in which the Catalyst in the form of fine powder was held
in suspension in Gas Stream. It was found that by carefully controlling the Catalyst
particle size and the velocity of gas moving through it, a Fluidized bed of Catalyst
would form which has the properties of liquid. In the fluidized system, finely
Powdered Catalyst is lifted into the Reactor by incoming oil, which immediately
vaporizes upon contact with the Hot Catalyst and after reaction is complete, it is
lifted into the regeneration zone. Cat Crackers using Powdered Catalyst in this way
are known as FLUID CAT CRACKING UNITS and most plants depend on this
principle, though in detail there are wide varieties of designs.

FUNCTION OF THE PLANT

The fluidized Catalytic Cracking unit catalytically cracks the Vacuum Gas oils from
VDU and FPU to various high-priced Hydrocarbons.
The Hydrocarbon vapours are separated into following products in Fractionation
and Gas concentration section.

1.1111111111 1. Fuel Gas

2. Liquefied Petroleum Gas (LPG)
3. Gasoline of High Octane Number
4. High Speed Diesel (HSD) Component
5. Light Diesel Oil (LDO) Component
6. Fuel Oil (FO) Component
UNIT CAPACITY:-

FCC Unit is designed to process 1.5 million tones per year of vacuum gas oil
(VGO) derived either from:
Case-1. 100% North Gujarat VGO
Case-2. 60 % IMP. VGO + 10 % (SG+BH) VGO. + 30% NG VGO
& Visbreaker Naphtha : 0.078 MMTPA.
& Visbreaker off gas : 0.037 MMTPA.

ON STREAM FACTOR : 8000 Hrs./ Year.

CONSUMPTION OF CHEMICALS:

Sr. Chemicals Requirement Remarks

No.
1 Equilibrium Catalyst 120MT / Charge Used in Start up
2 Fresh Catalyst 70-90 MT / Month Make up
3 Hydraulic Oil 9.5 M3 /Charge For slide value
operation
4 Caustic Soda 5.1 MT / Charge Used in Start Up
30.0 MT /Month Make up
5 Sand (8-16 mesh Size) 3.3 M3 / Charge Used in LPG Treater
(830-V-10)
6 Inert Gas 280 NM3/Hr WGC purging &
degassing
7 Tri. Sodium Phosphate 75 Kg /Month Steam Generation
8 Hydrazine Hydrate 45 Kg / Month Steam Generation
9 ZSM-5 2.0 MT /Month With fresh Catalyst
make up.

PROCESS FLOW DESCRIPTION:

A modern 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 go 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 given caustic wash 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:

i. Feed Pre-heat Section

ii. Catalyst Section
iii. Fractionation Section
iv. Gas Concentration Section
v. Caustic Treatment Section
vi. Steam Generation Section
1.) FEED PRE-HEAT SECTION:
Hot Vacuum Gas Oil from Feed Preparation Unit and VDU is received in
feed charge drum 820-V-04. Balance feed stock comes as cold feed from
storage tanks.
The raw oil passes through heat exchangers in the following sequence and gets
heated to 300-315 0C.

Sr. No. Service

i. Heavy Naphtha Exchanger
ii. Circulation LCO Exchanger
iii. Clarified Oil Exchanger
iv. Circulating HCO Exchanger
v. Slurry Exchanger

2.) CATALYST SECTION:

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 vapor from the catalyst
particles and returns these vapors to the reactor. To increase the stripping efficiency,
stripping steam is provided at following points, which is different from old reactor
stripper where only single point stripping steam was provided.

Reactor dome steam is also provided at the top of reactor by 2FC 7343 to avoid
coking inside dome area and purging of this area during start up.

The spent catalyst leaves the stripper through reactor standpipe to the
regenerator.

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 by the operator.
The regenerated catalyst leaves the regenerator through the regenerator
standpipe. A regenerated catalyst slide valve (RCSV), 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) is located on
the flue gas line , which controls the differential pressure between the reactor and
regenerator.
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.
The two-port slide valve located at the bottom of orifice chamber routes the
flue gases either to ‘CO’ Boiler or to the stack bypassing ‘CO’ Boiler.
A sacrificial cylinder is provided on the outlet nozzle or DDSV to protect the
conical portion of orifice chamber from erosion.

3.) FRACTIONATION SECTION

The cracked oil vapours at around 495-498 oC 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 trays and structured packing.

OVERHEAD SYSTEM
Vapors from the column top are condensed in air fin condenser and further
cooled in trim coolers. 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. A control valve on this line controls the top temperature of 820-C.

Rest of the liquid (unstable gasoline) is pumped by 820-P-10 A/B to 830-C-01

of GCU. 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.
A provision exists to inject combined wash water ex 830-V-03, 830-E-04 and
830-V-01 either to the inlet or outlet of 820-E-12 A to L through restriction orifices.

Water accumulated in the boot of 820-V-05 is pumped by pumps 820-P-12A/B

to SRU (Sulphur Recovery unit). Provision is there to route sour water to GRE sour
water stripper also.

SIDE DRAW OFF SECTION:

Heavy Naphtha: It is drawn from the first chimney tray counting from top.
Heavy naphtha enters the stripper on 1st tray through a level control valve. The
stripper is having 6 nos. of valve trays. Stripping steam is introduced at the bottom
of the stripper.
The vapours from stripper top return to the column 820-C-01 below 7th tray.
Stripped Heavy naphtha is taken to pumps 820-P-07 A/B and pumped to air fin
cooler and trim cooler.
The rundown flow is controlled by 820-FC-195 and can be routed to the
following:
i. HSD pool
ii. LDO pool - This line is now blinded because of low flash point
of heavy naphtha.
iii. Slop
iv. MS pool (Via flow controller 2-FC-3304)
v. PDS pool (Via flow controller 2- FC-3304)

A. LIGHT CYCLE OIL:

LCO is drawn from 2nd chimney tray from top (below 19th tray as per old
numbers)
LCO goes to stripper 820-C-03 on 1st tray through a level control valve.The
stripper is having 6 nos. of valve trays. Stripping steam is introduced at the
bottom of the stripper. The vapours from stripper top return to the column below
19th tray. Stripped LCO is taken to pumps 820-P-05 A/B and is pumped to BFW
exchanger 820-E-01, air fin cooler and trim coolers. Finally it is sent to storage
tank. R/D LCO down stream can be routed to:

i. LDO pool
ii. HSD pool
iii. Slops
iv. FLO header
v. FO pool
vi. DHDS Unit / DHDS
CIRCULATING LCO:
The other part of LCO is pumped by circulating reflux pumps 820-P-08 A/B to
the following:
LCO goes to raw oil exchanger 820-E-14 A/B through a flow control valve,
which is reset by 820-FC-297.
The other part goes as a heating medium to stripper Re-Boiler 830-E-07 under
30-FC-85. It is cascaded with stripper top vapour flow controller 30-FC-74.
A part of LCO ex 830-E-07 is used, as sponge oil for absorption is Sponge Oil
Absorber 830-C-02. The rich oil from 830-C-02 bottom joins LCO from 830-E-07
outlets. (For further details see GCU section)
Finally LCO stream ex 830-E-07 as well as 820-E-14 return to main column on
th
16 tray.

B. HEAVY CYCLE OIL :

HCO is drawn from 28th tray and is taken to pumps 820-P-06 A/B and
distributed to the following;
HCO is recycled to feed line after furnace
HCO goes to debutanizer Re Boiler in and returns to column 820-C-01 on 25 th
tray.
HCO goes to the raw oil exchanger and returns to the fractionating tower 820-
C-01 on 25th tray. One stream goes to LDO pool.
HCO goes to steam generator and returns to the fractionators 820-C-01 on 25 th
tray.

COLUMN BOTTOMS – SLURRY OIL:

The slurry oil collected from the bottom of 820-C-01 is pumped by 820-P-03
A/B to the following places.
To column bottoms steam generator 820-E-04. This stream returns to the
column on 32nd tray through a flow control valve, which is reset by 20-FC-147.

To raw oil exchanger 820-E-03 C/B/A in series, and returns to column on 32nd
tray. One stream goes to column bottom a quench. Another MCB stream provision
also given from 820 P 3A/B to 32nd tray through 2FC 2902.

The other part is routed through the raw oil exchanger 820-E-05, CLO cooler
820-E-06 A/B and is then pumped to LSHS/FO/Slops by 820-P-04 A/B.

Slurry from 820-P-03A/B discharges joins the feed to Reactor through a

control valve, which is reset by 2FC 7618.

Slurry from 820-P-03A/B discharges also joins the feed to slurry settler 820
V03 where the catalyst settles down at the bottom and clear oil comes out from the
top. This clear oil from slurry settler top is called clarified oil (CLO). The clarified
oil is divided into following two streams.

 A part return to column 820 C01 on 36 th trays.

  The other part is routed through the raw oil exchanger and then pumped to
storage.

4.) 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 830K01A and B through a flow controller –3FIO-11 and 830 HIC
3901 respectively.
Compressed gas from 1st stage of 830 K01A goes to following at around 6
Kg/cm2 pressure.

5.)CAUSTIC TREATING SECTION:

Gasoline from debutaniser bottom trim cooler 830-E-11 comes to the caustic
wash vessels 830-V-6 A/B, which operate in series

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 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 going out of 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.

6.) STEAM GENERATION SECTION:

MP steam is generated in the following steam generators:

i. HCO steam generators 820-E-07.

ii. Slurry steam generator 820-E-04.
iii. ‘CO’ Boiler 820-F-03.

-:HYDROCRACKER UNIT:-

What is hydrocracking?
 Hydrocracking technology plays the major role in meeting the need for cleaner
burning fuels, effective feed stocks for petrochemical operations, and more
effective lubricating oils.
Hydrocracking is an extremely versatile catalytic process in which feed stock
ranging from naphtha to vacuum residue can be processed in presence of hydrogen
and catalyst to produce almost any desired products lighter than the feed.
If the feed is naphtha, it can be converted into LPG and if feed is VGO as in
refinery, it can produce LPG, naphtha, ATF, and diesel in varying proportions as
per design requirements.
Hydrocracker does not yield coke or pitches as byproducts, entire feedstock is
converted into required product range, which is an important consideration in a
situation of limited crude oil availability and its rising prices.

Chemistry of Hydrocracking:-
Feedstocks for hydrocracking are composed of different hydrocarbon types such as
paraffins, cycloparaffins, aromatics and heteroatom containing compounds. All these
hydrocarbons undergo a variety of reactions. Some reactions important to
hydrocracking are discussed here.

Isocracking Reactions:
Examples of the principle hydrocracking reactions taking place in the ISOCRACKER
are given below. All of these reactions are exothermic. In general sulfur and nitrogen
molecules are cleaved from the sulfur and nitrogen containing hydrocarbon ring by
saturation (of the ring) and hydrogenation to yield H2Sand NH3. Cracking reactions
conserve rings to a great extent. Occasionally, there are more product molecules with
rings that feed molecules. Product paraffins tend to be branched chains with only minor
amounts of normal paraffins. To a great extent, the olefin saturation occurs only in the
progress of the reactions through the reactor.

Desulfurisation:
The fresh oil feed is desulfurised by hydrogenating sulfur containing compounds to
yield hydrogen sulfide. The H2S is subsequently removed from the reactor effluent,
leaving only the hydrocarbon in the product. Typical desulfurisation reactions convert
thiophenes to thiols to straight chain or branched paraffins and hydrogen sulfide.

Denitrification:
Nitrogen is removed from the feedstock by hydrogenating nitrogen containing
compounds to form ammonia. The ammonia is subsequently removed from the reactor
effluent, leaving only the hydrocarbon in the product. Typical ISOCRACKING
reactions with nitrogen compounds include hydrogenation of pyridines to form
paraffins and ammonia, quinolines to form aromatics and ammonia, pyrroles to form
paraffins and ammonia. The heat of reaction of denitrification reactions is about 630-
705 kcal/Nm3 of hydrogen consumed.
R-CH2CH2CH2NH2 + H2 ========> R-CH2-CH2-CH3 + NH3

0lefin Saturation:
 Hydrogenation of olefins is one of the most rapid of the reactions taking place. This
rapidity is the reason essentially all olefins are saturated. The heat of reactions for these
reactions is about 1320 kcal/Nm3 of hydrogen consumed.
R-CH2CH=CH2 + H2 ==========> RCH2CH2CH3

Aromatic Saturation:
Some of the aromatics in the feed are hydrogenated to naphthenes. Aromatic saturation
amounts for the significant portion of both the total hydrogen con sumption and the
total heat of reaction. Heats of reactions vary about 375-750 kcal/Nm3 of hydrogen
consumed depending upon the type of aromatic being saturated. In general, high
pressures and lower temperatures result in a greater degree of aromatic saturation

Hydrocracking:
Hydrocracking of large hydrocarbon molecules into smaller molecule occurs in nearly
all processes carried out in the presence of excess hydrogen. The heat release from the
hydrocracking reactions contribute appreciably to the total heat liberated in the reactor.
Heat of reaction is of the magnitude of 470 kcal/Nm 3 of hydrogen consumed. Small
amounts of naphtha and light hydrocarbons are produced, and some cracking reactions
involving the heavy molecules contribute to a decrease in product specific gravity. The
light hydrocarbons are temperature dependent. Thus the amount of light ends produced
increases significantly as temperatures are raised to compensate for reduced catalyst
activity.

Hydrocracking in G.R.

Primary function Hydro cracker unit is to maximize middle distillate production

in Gujarat Refinery. Feed to the unit consists of Vacuum gas oil (VGO) from new
feed preparation unit (FPU) which is nothing but a vacuum distillation unit
processing the North Gujarat Reduced Crude Oil.

The primary products from HCU are :

L.P.G
Stabilized Light Naphtha
Heavy Naphtha
Aviation Turbine Fuel (ATF)/ Superior Kerosene (SK)
High Speed Diesel (HSD)

The Hydrocracker is made-up of three major sections :

The make-up Hydrogen compression section,

the reactor section (two stage) and
the distillation section.
 In the reactor section, the feed stock is combined with Hydrogen at high
temperatures & pressures and is catalytically converted to lighter transportation
fuels.

The reactor section is composed of the first stage reactor and the second stage
reactor.
The make-up Hydrogen compression section provides hydrogen to each reactor
section, the reaction products are separated and cooled.
The distillation section consists of the atmospheric fractionation, light ends
recovery, LPG treating and a vacuum column.

The unit is designed to process 3600 TPA of VGO to convert it fully into products
boiling below 370 deg. Cent. i.e. Diesel, lighter fractions. As the quality of Naphtha,
ATF, SK, HSD meets the specifications, no post treatment is given.

However, LPG is given a mild caustic wash and fuel gas is desulfurised by di-ethanol
amine (DEA) absorption for better environment management.
Hydrocracker Unit operates under two different Catalyst condition Viz. Start of Run
(SOR) & end of Run (EOR). When the catalyst is new or freshly regenerated, it is start
of Run conditions. The Catalyst gets deactivated due to Coke deposition (about 12 - 18
months) and requires regeneration to operate under design stipulations. The operating
condition just before regeneration is called EOR operation.