SUMMER TRAINING REPORT

INDIAN OIL CORPORATION LTD. HALDIA

PERIOD OF TRAINING

(23.05.2019 – 19.06.2019)

REPORT PRESENTED BY:

STUDENTS FROM DEPARTMENT OF CHEMICAL ENGINEERING

 SREERAM THAMMANA (NIT DURGAPUR)

 SUPRATIM DEY (NIT DURGAPUR)
 SONU DIXIT (NIT DURGAPUR)
 SUMANT KUMAR (NIT DURGAPUR)
 RAHUL BANERJEE (BIT MESRA)
 SHIVAM PRAJAPATI (NIT WARANGAL)
 BIRAG SAHA (NIT WARANGAL)

SUBMITTED TO
MR. SANDILYA CHARI
LEARNING AND DEVELOPMENT.
 Acknowledgement
We express our heartiest gratitude towards each and every person who made our
vocational training here at IOCL, Haldia a really pleasant and smooth experience.
Moreover, we are greatly indebted to Indian Oil Corporation for giving us this
wonderful opportunity to have a great firsthand experience about the physical
implications of our theoretical knowledge at the industrial level.

We would like to express our sincerest gratitude towards our training officer Mr.
Sandilya Chari who guided us wonderfully throughout the training period at each
step, with utmost care. We would also like to thank Mr. Bhaskar Sen Sir who was
very kind to formulate a complete schedule for the timely visit to each of the
respective units in an orderly fashion. Also, we wish to thank all the respective unit
supervisors who were very generous and helpful and made sure that we got a very
good idea about the particular units and its role in the refinery. The names of the
supervisors are-

 Mr. Chandan Kumar (FOB)

 Mr. Kanai Chatterjee (LOB)
 Mr. R.L. Sahoo (DHDS)
 Mr. U.K. Jana (Bitumen)
 Mr. K.C. Nayek (ETP)
 Mr. P.P. Narzary (OM&S)
 Mr. R.K. Puram (OHCU/HGU)

And lastly, we would like to thank all the shift-officers, the operators and everyone
else who helped us to understand the various equipments in the field and thus make
our training at IOCL, Haldia a memorable experience.
PERSONS TO WHOM REPORTED

TRAINING BLOCK SIGNATURE OF TRAINING

I/C
FUEL OIL BLOCK:
(Mr. Chandan Kumar)
LUBE OIL BLOCK:
(Mr. Kanai Chatterjee)
DIESEL HYDRO DE
SULPHURISATION UNIT:
(Mr. R.L. Sahoo)
BITUMEN:
(Mr. U.K. Jana)
ETP:
(Mr. K.C. Nayek)
OM &S:
(Mr. P.P. Narzary)

OHCU:
(Mr. R. K. Puram)
 BRIEF INTRODUCTION OF HALDIA
REFINERY
Haldia Refinery, one of the eight 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 Hoogly and
Haldi.

From an original crude oil processing capacity of 2.5 MMTPA, the refinery is now
operating at a capacity of 7.5 MMTPA at present. Capacity of the refinery was
increased to 2.75 MMTPA through de-bottlenecking in 1989-90, and to 3.75
MMTPA in 1997 with the installation/commissioning of the second Crude
Distillation Unit of 1.0 MMTPA capacity. Products like MS, HSD and Bitumen are
exported from this refinery.

Haldia Refinery is currently 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, the refinery is producing BS-II and Euro-III equivalent HSD (part
quantity) at present. Refinery also produces ecofriendly 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. In order to meet the
Euro-III fuel quality standards, the MS Quality Improvement Project has been
commissioned in 2005 for production of Euro-III equivalent MS. The refinery
expansion to 7.5 MMTPA as well as a Hydrocracker project has been approved,
commissioning of which shall enable Haldia Refinery to supply Euro-IV and Euro
– III HSD to the eastern region of India.
PREFACE
This report has been prepared based on the summer training performed in I.O.C.L,
Haldia. IOCL is the India’s largest downstream company tasked with handing
crudes imported from Arabian countries transported by ship Indian Oil Corporation
Ltd. (IOC) is the flagship national oil Company in the downstream sector. It is one
of the most advanced plants in India for oil refining and has been using American,
Japanese & Russian technology. The Indian oil group of companies owns and
operates 9 refineries directly of India’s 24 refineries and 2 more with some shares,
with a combined refining capacity of 1.2 million barrels per day. These two
refineries of subsidiary Chennai Petroleum Corporation Ltd. (CPCL) and one of the
Bongaigaon Refinery and petrochemicals Limited (BRPL). The 9 refineries are
located at:

• Guwahati (Assam)

• Barauni (Bihar)

• Koyali, Baroda (Gujarat)

• Haldia (W.B.)

• Mathura (U.P.)

• Panipat (Hr.)

• Paradweep (Orissa)

• Bongaigaon (Assam)

• Digboi (Assam)
HOW IS HALDIA REFINARY UNIQUE?
1. First Indian refinery to receive ISO-9002 certificate.

2. Incorporating 70% indigenous equipment for the first time in India.

3. India‟s only refinery producing Bright stock-a lube oil base stock for making
lube oil which is used in heavy duty equipment.

4. One of the India‟s three lube oil refineries producing high grade lube base feed
stocks.

HALDIA REFINERY PRODUCTS

1. Liquefied petroleum Gas (LPG)
2. Straight run naphtha (SRN)
3. Motor spirit (MS)
4. Bitumen
5. Superior Kerosene oil/ Aviation Turbine Fuel (ATF)
6. Russian Turbine Fuel (RTF)…. Presently not prepared
7. Mineral Turpentine oil (MTO)
8. High speed diesel (HSD)
9. Jute Batching Oil (JBO)
10. Light Neutral Lube oil base stock (LN-LOBS)
11. Bright Neutral Lube oil base stock (BNLOBS)
12. Fuel gas
13. Slack wax inter-neutral (IN-SW)/ Slack wax Bright neutral (BN-SW)
14. Carbon block feed stock (CBFS)
15. IOC process oil
OVERVIEW
This report contains a brief study on the following units which we visited
in summer 20/05/19 to 15/06/19 for 25 days vocational training programme at
IOCL Haldia. The units are:-

 Fuel Oil Block (FOB)

 Lube Oil Block (LOB)

 Diesel Hydro-DeSulphurisation Unit (DHDS)

 Bitumen Filling Station

 Effluent Treatment Plant (ETP)

 Oil Management And Storage (OMS)

 Once Through HydroCracking Unit (OHCU)

The study based project has been completed using the data provided
to us by the respective supervising officers in each of the units and
the data found on the internet. The objectives of the study are:-

 To get an exposure of the actual working environment within

a multi- national.

 To thoroughly understand the process dynamics of all the

units inside the control panels.

 To understand the benefits of coastal location of the refinery.

 To see the different machines and how it works.

 Basic Refinery Processes
The various refinery processes are given below in an overview form so as to get an idea.
Block Flow Diagram of Haldia Refinery
 FUEL OIL BLOCK (FOB)
Fuel oil block is one of the main blocks of IOCL refinery where crude oil is
taken as feed from storage tank (OM&S) and distillated into different
components which include Fuel gas, Naphtha, Kerosene, LGO, VGO and
RCO. In Fuel Oil Block, other than the production of the above components,
their treating is also done to meet the various norms set for quality requirement
and pollution control.

The units in Fuel Oil Block are as follows:

1. Crude Distillation Unit 1&2 (CDU 1&2)

2. Naphtha Hydro-treating Unit (NHDT)
3. Catalytic Reforming unit (CRU)
4. Kero Hydro-Desulphurisation unit (KHDS)

1. CRUDE DISTILLATION UNIT (CDU 1&2)

CDU 1&2 are the two distillation units present in Fuel Oil Block. CDU
1 is the older unit and is used for distillation of high Sulphur crude oil.
CDU 2 is used for the processing of low as well as high Sulphur crude
oil.

The components we are getting from distillation unit are as follows-:

1. Fuel gas

2. LPG

3. Naphtha

4. Kerosene/ATF

5. Light Gas Oil (LGO)

6. Heavy Gas Oil (HGO)

7. Reduced Crude Oil (RCO)

Crude oil is heated to 120 0C in a set of pre-heat exchangers and fed to

‘de-salter’. Calcium, Magnesium salts present in the crude is desalted
to 95 % in the de-salter. Some amount of metals are also removed as
they lead to catalyst poisoning. The de-salter consists of two
transformers placed on top of it which create an alternating electric
field that precipitates out the salts and metals.
Crude temperature is raised to 200 0C in a second set of heat
exchangers and then sent to a ‘pre-fractionation column.’ This is
done to remove some lighter products which in turn helps in reducing
the load on the furnace.

Overhead product-Fuel gas and a part of naphtha

Bottom product-Pre fractionated crude

Crude further heated to 260 0C in heat exchanger and then to 350 0C in

a ‘furnace’.
It is then sent to the atmospheric distillation column to obtain multi
component product streams which are mentioned above.
In ADU, each product stream is passed through a stripping section for
reflux and then passed through a series of heat exchangers for heat
recovery.
The top product from ‘Pre-fractionator’ consists of fuel gas and some
amount of Naphtha. This product along with the Naphtha obtained in
ADU are sent to ‘Naphtha Stabilizer’ where the two streams of ‘C1-
C4’ and ‘C5-C8’ get separated.
The top stream ‘C1-C4’ is sent to ‘De-Ethanizer’ Column where ‘C1-
C2’ (fuel gas) and ‘C3-C4’ (LPG) get separated. The fuel gas is sent to
‘Amine Treating Unit’ to remove H2S. LPG is sent for processing or
to ‘De-Propanizer’ Column to separate Propane and Butane. The
Propane is sent to Propane De-Asphalting Unit in LOB.
2. NAPTHA HYDRO-TREATING UNIT (NHDT)
This unit prepares the straight run naphtha for CRU by the elimination of Sulphur.
CRU unit has a Pt catalyst on Alumina Support which gets deactivated in the
presence of Sulphur, Nitrogen. Sulphur also causes corrosion, coking and many
environmental issues. The feed and hydrogen are mixed and send to the heat
exchanger and furnace to raise the temperature of about 250-260 0C. The feed
mixture is sent to the reactor contains Ni-Mo catalyst on alumina support

The hydrogenation reactions take place where the Sulphur, Nitrogen and Oxygen
react with hydrogen to form H2S,NH3 and H2O gas and released from the top. The
hydro-treated naphtha passed to the Sulphur guard which absorbs the Sulphur and
then send to the CRU (catalytic reforming unit).

RSH + H2  H2S + RH
 .

2. CATALYTIC REFORMING UNIT (CRU)

The purpose of CRU is to increase the octane number of MSQ which improves the
anti-knocking property. Octane number is the percent of iso-octane present in a
mixture of iso-octane and n-heptane. Here in CRU, aromatization, isomerization,
unsaturation, process take place The CRU consists of three reactors and three
furnaces because the reaction is endothermic reaction as it consumes hydrogen. The
reactor consists of a platinum catalyst on A which reforms the naphtha. The final
product is reformed naphtha which is sent to the Motor Quality Upgradation Unit.
3. KERO HYDRO DE-SULPHURISATION UNIT
(KHDS)

This unit removes Sulphur from kerosene distillate cut produced from
atmospheric distillation unit. Kerosene/ATF is preheated in a series of heat
exchanger and furnace to raise the temperature of about 280 0C. The feed is then
sent to the desulphurization reactor filled with Co-Mo catalyst.
The Sulphur is converted to H2S which is stripped off by the amine wash. The
final product is treated kerosene/ATF which contains zero moisture, zero silver
and copper corrosion, conductivity of 300-unit, freezing point -48-55 deg C and
smoke point for Kero is 18 deg C , ATF is 15 deg C.
 LUBE OIL BLOCK (LOB)
Lube Oil Block comprises of the following units:

 Vacuum Distillation Unit

 Propane De-Asphalting Unit

 Furfural Extraction Unit

 Solvent Dewaxing Unit

 Hydro finishing Unit

 Vis-breaking Unit

 Catalytic Iso Dewaxing Unit (U-84)

The typical lube oil base stock processing circuit is shown below for Haldia
Refinery.

Lube Processing circuit in Haldia Refinery

KV, Colour &
Gas Flash Point
VI, CCR Pour Point Stability

Naphtha VGO Vacuum Waxy De-waxed Lube

Kero Distillates Raffinates oils Base Oils
Atmospheric distillation

Vacuum distillation

Diesel
Solvent Extraction

150N
Solvent De-waxing or
Catalytic De-waxing

Hydrofinishing

Crude
500N
Oil
HN

150BS
VR DAO
RCO
Propane De-Asphalting
Important Properties of Lube Oil

The major properties for any LOBS are as follows:

1. Kinematic Viscosity (kV)

 It dictates the reducing power of the frictional resistance between two

moving parts due to the presence of the lube oil.

2. Viscosity Index (VI)

 It defines the rate of change of kinematic viscosity with temperature, thus

governing high temperature applications viz. inside engines or compressor
crankcases etc.

3. Flash Point

 It indicates the lowest temperature, at which vapors of the material will

generate a flash momentarily.

4. Pour Point

 It indicates the lowest temperature at which the oil would remain in liquid
state, thereby maintaining its fluidity intact, as because very low
temperatures may be encountered in land of caprice climate (e.g. at Leh
etc.).

5. Color

 Lube Oil Base Stock should be water-like in appearance, the color that is
seen in most of the marketed lube oils are due to the additives that are added
in LOBS. This color is imparted mainly due to unsaturated/aromatics
leftover in the finished LOBS.
 6. Oxidation Stability

 Oxidation stability is required so as to reduce any chance of polymerization

(due to contact with oxygen at some elevated temperature. This happens due
to the presence of unsaturates.

1. Vacuum Distillation Unit (VDU)

Purpose: -To distil the RCO under vacuum for producing vacuum distillates for
preparing feedstock for LOBS manufacturing.
Diesel and VR are by products and residue respectively

Feed RCO (Reduced Crude Oil) Ex FOB - CDU Bottoms

Products Gas Oil/ Diesel
Spindle Oil
Light Oil
Inter Oil
Heavy Oil
Vacuum Residue (VR) or Short Residue (SR)
Unit
250m3/hr, with Arab Mix /Upper Zakum RCO
Capacity
Distillation
Parameters
Pressure 70 mmHg Absolute
Temperature 360-400 C

Process Description: RCO is preheated in a series of heat exchangers (pre-heat

exchanger train) by exchanging heat with the high temperature product streams and
then passed through two numbers of fired heaters (furnaces) to achieve temperature
of ~400 C. This heated stream is flashed in a vacuum distillation column operating
with top pressure of 70 mmHg (Abs). Gas oil reflux is given at the top. Also, an
internal pump around below the Light Oil draw tray helps to remove heat from the
column. Products like SO, LO, IO and HO are drawn from different draw nozzles
from the column. Each product is stripped with stripping steam in their respective
stripper columns to remove the lighter components and thereby increases the flash
pints of the products. All these products are cooled in the feed preheat exchangers
followed by water or tempered water coolers. VR is drawn from the bottom of the
column and is routed to tanks after exchanging heat with the feed stream followed
by steam boilers and tempered water coolers.

Advantages: -As the boiling points reduce with decrease in pressure, RCO need
not be raised to very high temperature for further distillation. At high cracking
phenomena shall get promoted leading to coke formation in pipe lines, columns,
vessels etc. Coke deposition is strictly undesired as it leads to blockage/ clogging
of pipes and restricts flow leading to unwanted unit interruptions. Vacuum
distillation helps to avoid such occurrence.
• RCO feed temp: 90-115 deg C
• Preheat Temp: 285 deg C
• Coil Outlet Temp: 400 deg C
• Vac Tower Flash Zone Pr.: 120-130 mm Hg at 400 deg C
• Vac Tower top Pressure: 70 mm Hg (Abs)
• Vac Tower Top Temp: 80 deg C
• Stripping Steam: 6.5-10 Mt/hr.
• Product Draw off temp: 232, 245, 333 & 370 for SO, LO, IO & HO
• Bottom Quench: 5 m3/hr
2. Propane De - Asphalting unit (PDA)
Purpose: - To recover the valuable oil left in the Vacuum Residue from VDU
bottoms. Around 25-30 % oil is left in the VR/ SR which can‟t be recovered in the
VDU. The recovered oil called DAO (De-asphalted Oil) is a very good feed stock
for high viscosity LOBS manufacturing.

Feed VR (Vacuum Residue) from VDU bottoms

Products DAO (De-asphalted Oil)

Asphalt

Unit
800000 MT/Yr
Capacity
DAO is recovered by means of Extraction process with liquid
Methodology propane as a solvent. Propane dissolves the oil and rejects the
asphalts. Propane has a reverse solubility for asphalt and thus
 DAO quality improves with increase in extraction temperature.
Pressure 38 Kg/ Cm2(g)
Temperature 60-80 C
Propane to
6 to 12
Feed Ratio

Process description: -VR feed is diluted with propane solvent and sent to
extractor columns C 01A/B/C and C 110. Solvent propane is also fed to the
extractor where counter current mass transfer takes place. Propane dissolves the oil
part and comes out from the top as DAO Mix (contains around 80% propane)
while the asphalt being heavy is withdrawn from the bottom as Asphalt Mix.
Propane is recovered both from DAO Mix and Asphalt Mix and re-circulated in the
unit again. ROSE (Residual Oil Super Critical Extraction) technology has been
used to recover the propane from the DAO Mix phase where DAO Mix Phase is
taken to its critical temperature and pressure conditions. The propane at this state is
just below its boiling point and gets separated from DAO in a pure form in liquid
state.

Advantages: Recovery of high value DAO which can be upgraded to high

viscosity LOBS- BN (Bright Neutral) and BP (Bright Pale) grades. BN processing
also gives wax in SDU which is further upgraded to high valve Micro Crystalline
Wax product in WHFU (U 39).

Operating variables: -Temperature: Rise in extraction temperature rejects more

asphalt and thus DAO quality improves but yield decreases.
Propane to Feed Ratio: Increase in ratio increase DAO yield but degrades the
quality.

3. Furfural extraction unit

Purpose: -To remove the aromatic hydrocarbons from the Vacuum Distillates (SO,
LO, IO, HO) and DAO for improving Viscosity Index (VI) of the products

Feed Vacuum Distillates (SO, LO, IO, HO) and DAO

Products Raffinates of SO, LO, IO, HO and DAO

Extracts of SO, LO, Io, HO and DAO

Unit Capacity 515000 MT/ Annum

 Separation process is Extraction with a solvent named
Furfural. The solvent has high affinity for aromatics and
dissolves them thereby creating two phases- Raffinate Mix
Phase (Lean in aromatics) and Extract Mix Phase (rich in
Methodology aromatics). Solvent is recovered from both the streams and
re-circulated back to the unit after proper drying (removal of
water). Raffinate and Extract products are routed to their
respective tanks after cooling in the preheat exchangers
followed by water coolers.
Pressure 1-2 Kg/ Cm2(g)
Temperature Top 95-130 C, Bottom 45-80 C
Solvent to Feed
1.2 to 2
Ratio

Process description: -De-aerated Feed and solvent are fed to an extractor column
in a counter current direction where mass transfer takes place. Solvent is in
continuous phase while the feed is in the distributed phase. The raffinate mix and
extract mix are heated in their respective furnaces and flashed in their respective
recovery circuit columns. The flashed vapors are condensed and collected in a
solvent dryer column to remove water. The dry solvent is re-circulated back and
Raffinate/ Extract products are routed to their respective storage tanks .

Operating variables: -Temperature: Rise in extraction temperature rejects more

asphalt and thus DAO quality improves but yield decreases.
Propane to Feed Ratio: Increase in ratio increase DAO yield but degrades the
quality.
5. Vis-breaker unit
Purpose: -To convert the high viscosity feed stock like VR/Asphalt to low
viscosity products like VB Tar/ Furnace Oil.

Feed Vacuum Residue/ Asphalt/ Heavy Extracts

Products VB Tar/ FO

VB Gas oil, VB Gasoline and Fuel Gas

Process :-A mild thermal cracking process, a common process wherein long chain
hydrocarbon molecules in heavy feed stocks are broken into small molecules
having low viscosity, thereby leading to a viscosity reduction of feed stock.
Feed stock is heated to relatively lower temperature (435-445 Deg C) in a furnace
and partly cracked VB charge is hold in a Soaker Drum for longer residence times
(25-30 min) to achieve the required conversion

Process description: -The feed after passing through a series of preheat exchanges
is fed to a furnace to raise the temperature to around 440 C. This stream is passed
through a soaker vessel where a residence time of around 30 minutes is given. The
soaker is operated at a pressure of around 10 Kg/ Cm2g. The soaker outlet is
fractionated in a column where different products are separated to produce on spec
Furnace Oil/ VB Tar.

Operating variables: -Furnace coil outlet temperature

Soaker pressure
Residence time
Operating parameters: - Furnace outlet temperature: 440 – 443oC
Back Pressure: 10-12 kg/cm²g.
Residence Time: 1200-1800 Second
6. CIDWU (catalytic Iso De Waxing unit)
Purpose: -Catalytic De-Waxing unit has the objective of producing superior grade
Group II LOBS.

Feed Raffinates of (SO, LO, IO, HO) and DAO

Products De-waxed oils of SO, LO, IO, HO and DAO

Heavy Distillates, Light distillate and Unstabilized Naphtha

Unit Capacity 200000 MT/ Annum of De-waxed Oil

Conversion of Wax component in Raffinate feed to Non- waxy
components
Process is isomerization of the N-Paraffins to Iso-Paraffins
N Paraffins - Waxy Nature
Methodology
Iso- Paraffins - Non-Waxy Nature
Feed is purified in a Hydrotreatment Reactor and then de-waxed in
the De-waxing reactor followed by a Hydro-finishing reactor.
Vacuum fractionation of the De-waxed, Hydro-finished product for
on grade de-waxed oil products.

System pressure
Reactors Temperature
Operating Variables
Space velocity in the Reactors
Hydrogen Circulation Rate
Parameter Operating Range
Make up H2 flow 3500-5500 Nm3/h
System pressure 112.5 kg/cm2g
R-01 320-365 deg C
R-02 320-365 deg C
R-03 225-260 deg C
 H2 to HC flow ratio 500-650 Nm3/m3 liquid feed

Process Description: - Feed after preheating is elevated to high temperature in a

furnace and fed to the HDT reactor. The sweetened feed is stripped off H2S + NH3
in a stripper with pure hydrogen gas and fed to the de-waxing reactor after
elevating to a designated temperature in a furnace after pre-heating. The de-waxing
reactor outlet is then fed to a hydro-finishing reactor. Vapors after separation in a
high-pressure separator is recycled back to the system. The liquid part from the
stripper is fractionated in stages to remove the lighter components for achieving
desired specifications. Vapors from Hydrogen stripper are sweetened in an amine
wash followed by a water wash column and the sweet gas is recycled in to the
system.

Advantages: -Production of Group II LOBS with increased yield.

 4.Hydro finishing unit
Purpose: - To improve the color and the color stability of lube base stocks

Feed De-Waxed Oils from SDU

Products Finished LOBS

Unit Capacity 200000 MT / Annum

Process: -The process is a mild hydro treating one, using a catalyst in presence of
Hydrogen at high temperature and pressure.
 Removes contaminants
 Sulfur
 Nitrogen
 Unsaturates
At high hydrogen partial pressure and in presence of the catalyst, Sulfur &
Nitrogen in the feed get converted to Hydrogen sulfide and Ammonia respectively.
Also, unsaturates get saturated resulting in stable products

Parameter’s name Operating range

Reactor‟s outlet temperature 220-340 deg C

Furnace COT 210-330 deg C

Reactor dP 0.5-1.5 kg/cm2g (max. 3.5 kg/cm2g)

System pressure 55-60 kg/cm2g

 Make up H2 flow/purity 400-450 kg/h

Process description: -Feed mixed with hydrogen is passed through preheat

exchangers followed by a furnace to reach the desired temperature level. This
stream is fed to a reactor. Reactor outlet after cooling is separated from the vapors.
The liquid part is tripped off of lighter components in a vacuum column. Product
from the column bottom is sent to storage. The vapor part after purification is re-
circulated back using the recycle compressors.
 Diesel Hydro Desulphurization Unit (DHDS)

The Diesel Hydro De-sulphurisation Unit is based on union fining process,

designed to process distilled oil. Petroleum fractions contain various naturally
occurring contaminants like Sulphur, nitrogen and metal compounds which lead to
corrosion, pollution and causes difficulty in further processing the material. The
union fining process is a fixed bed catalytic process for hydrotreating feed stocks.
The process uses catalytic hydrogenation to upgrade the quality of petroleum
distillate fractions by decomposing contaminants. Union fining is designed
primarily to remove Sulphur and nitrogen. Union fining catalysts are composed of
Nickel or Cobalt with Molybdenum oxides on an alumina base.

Sulphur Removal:
Feed stocks containing mercaptan, sulphide and disulphide are easily converted to
H2S. This H2S is absorbed in amine which becomes rich amine and sweeten the
feed stock. H2S is further stripped off the rich amine in an Amine Recovery section
and converted to Sulphur.

Nitrogen removal:
Denitrogenation is more difficult than desulphurization. Feed stocks are
hydrogenated and formation of NH3 occurs. This NH3 is stripped off from the feed
stock.

Oxygen removal:
Organically combined oxygen is removed by hydrogenation of carboxyl bond
forming water and corresponding hydrocarbon.
Phenol + H2 = Benzene + H2O

Olefin saturation:
Olefin saturation reaction proceeds very rapidly and have high heat of reaction.

Aromatic saturation:
These reactions are most difficult and are very exothermic.
Benzene + H2 = Cyclohexane

Metal removal:
Metals are retained on the catalyst surface by adsorption. Removal of metals
generally occurs from top of catalyst bed and catalyst has certain maximum
tolerance for retaining metals. The total metal retention capacity of the catalyst
system can be increased by using guard reactor or guard bed of catalyst designed
for demetallisation.

The DHDS block consists of the following units:

1. Diesel Hydro De-sulphurisation Unit (DHDS)
2. Vacuum Distillation Column II (VDU II)
3. Resid Fluidized Catalytic Cracking Unit (RFCCU)
4. Motor Sprit Quality Upgradation Unit (MSQU)
5. Sulphur Recovery Unit (SRU)
6. Hydrogen Generation Unit (HGU)
7. Nitrogen plant/ Air plant/ Amine Regeneration Unit (ARU)/ Sour Water
Stripper (SWS)
 1. Diesel Hydro De-Sulphurisation Unit (DHDS)

The process involves hydrogenation of Sulphur and nitrogen compounds that are
present in diesel and decomposing the contaminants to upgrade quality of diesel.
Hydrogenation results in the formation of H2S which is absorbed into a
countercurrent flow of amine. The rich amine is sent to amine recovery unit for
regeneration of lean amine. The process also saturates the olefins and aromatic
compounds present in diesel.
Following are the chemical reactions taking place other than Sulphur removal, in
hydro de-sulphurisation process:
1. Nitrogen removal- Denitrogenation is a very difficult process and occurs
during hydro-treating.
2. Oxygen removal- Organically combined oxygen is removed by
hydrogenation of the carboxyl bond, forming water and corresponding
hydrocarbon.
3. Olefin saturation- The linear and cyclic olefins are converted to straight
chain molecules after hydrogenation.
4. Aromatic Saturation- Aromatic saturation is most difficult among all
reactions mentioned just above.
Other side reactions- These involve metal removal, hydro-cracking reactions etc.
 PROCESS FLOW DIAGRAM OF DHDS

2. Vacuum Distillation Unit (VDU II)

It is used for processing of High-Sulphur Crude. Reduced crude received from the
atmospheric unit is the feed stock of VDU. Basically, reduced crude oil (RCO)
cannot be distilled at the CDU operating conditions as they are very heavy. And if
temperature is increased, then excessive coke formation occurs. So it is distilled
under vacuum (70 – 80 mmHg) which will decrease the boiling points of the heavy
hydrocarbons and can be separated into GO, SO, LO, IO, HO, Vac slop, VR.
 PROCESS FLOW DIAGRAM OF VDU II

3. Resid Fluidized Catalytic Cracking Unit (RFCCU)

Fluid catalytic cracking (FCC) is one of the most important conversion processes
used in petroleum refineries. It is widely used to convert the high-boiling, high-
molecular weight hydrocarbon fractions of petroleum crude oils to more valuable
gasoline, olefinic gases, and other products. The feedstock to an FCC is usually
that portion of the crude oil that has an initial boiling point of 340 °C or higher at
atmospheric pressure and an average molecular weight ranging g from about 200 to
600 or higher. This portion of crude oil is often referred to as heavy gas oil or
vacuum gas oil (HVGO). The FCC process vaporizes and breaks the long-chain
molecules of the high-boiling hydrocarbon liquids into much shorter molecules by
contacting the feedstock, at high temperature and moderate pressure, with a
fluidized powdered catalyst.

Reactor and Regenerator

The reactor and regenerator are considered to be the heart of the fluid catalytic
cracking unit. The preheated high-boiling petroleum feedstock (at about 315 to 430
°C) consisting of long-chain hydrocarbon molecules is combined with recycle
slurry oil from the bottom of the distillation column and injected into the catalyst
riser where it is vaporized and cracked into smaller molecules of vapor by contact
and mixing with the very hot powdered catalyst from the regenerator. All of the
cracking reactions take place in the catalyst riser within a period of 2–4 seconds.
The hydrocarbon vapors "fluidize" the powdered catalyst and the mixture of
hydrocarbon vapors and catalyst flows upward to enter the reactor at a temperature
of about 535 °C and a pressure of about 1.72 bar.

The reactor is a vessel in which the cracked product vapors are: (a) separated from
the spent catalyst by flowing through a set of two-stage cyclones within the reactor
and (b) the spent catalyst flows downward through a steam stripping section to
remove any hydrocarbon vapors before the spent catalyst returns to the catalyst
regenerator. The flow of spent catalyst to the regenerator is regulated by a slide
valve in the spent catalyst line.
Since the cracking reactions produce some carbonaceous material (referred to as
catalyst coke) that deposits on the catalyst and very quickly reduces the catalyst
reactivity, the catalyst is regenerated by burning off the deposited coke with air
blown into the regenerator. The regenerator operates at a temperature of about 715
°C and a pressure of about 2.41 bar, hence the regenerator operates at about 0.7 bar
higher pressure than the reactor. The combustion of the coke is exothermic and it
produces a large amount of heat that is partially absorbed by the regenerated
catalyst and provides the heat required for the vaporization of the feedstock and the
endothermic cracking reactions that take place in the catalyst riser. For that reason,
FCC units are often referred to as being 'heat balanced'.
FCC increases the octane no of the Motor spirit produced by the CDU by
increasing the amount of the unsaturation and cyclic compounds, thereby
increasing the anti- knocking characteristics of that fuel.

4. Motor Sprit Quality Upgradation Unit (MSQU) (85/ 86/ 87)

The unit is commissioned with the aim to produce superior quality gasoline. The
main objective of the unit is to convert the straight chain hydrocarbons, C5 - C6
paraffin to branch chain, or olefins to improve the octane number. As benzene is
 carcinogenic so benzene saturation is an important factor in this unit. Reactions of
type desulfurization, isomerisation, and benzene saturation olefin saturations are
done in these units. The light FCC gasoline obtained after gasoline splitting in unit
87 is blended with heavy reformate from unit 85, isomerate from unit 86, heart cut
FCC gasoline from unit 87, and heavy gasoline after hydrodesulphurization in unit
87 are blended proportionately for octane improvement and desulfurization in the
blending header to get MS of desired octane number.

BLOCK DIAGRAM OF MSQU

5. Sulphur Recovery Unit (SRU)

The Sulphur Recovery Unit is designed to recover sulphur from the sour vapours
originating from the following sources.

 Amine Regeneration Unit

 Sour water stripper
The process is a combination of conventional Claus process and the recently
developed process for the selective oxidation of hydrogen sulphide. The SRU
consists of the following sections:

 A knock out drum for the feed gas stream and fuel gas stream
 A Claus section, consisting of a thermal stage and three reactor stages
 A SUPER CLAUS stage
 A thermal incinerator, burning the tail gas and vent gas of the sulphur
 Degassing system
 Sulphur pit with degasifying facilities and sulphur yards.

6. Hydrogen Generation Unit (HGU)

Used for generation of Hydrogen for quenching and de-sulfurization. HGU can be
divided into:
 Predesulphurisation
 Desulphurization
 Reforming
 CO – conversion
Predesulphurisation: Here the organic Sulphur compounds are removed from the
naphtha by catalytic conversion to Hydrogen Sulphide which is separated from
naphtha from distillation. It does not yield sufficiently low Sulphur concentration
in the feed to prevent poisoning of the feed naphtha reforming catalyst, so a final
desulphurization must also be performed. Hydrogen sulphide is removed by
stripping in the H₂S stripper and then sent to final desulphurization section.
Final Desulphurization section: The sweet naphtha from the predesulphurisation
section contains a few ppm Sulphur and chlorine compounds. In Sulphur and
chlorine are completely removed in the final desulphurization section.
It has 3 reactors:
1. hydrogenator loaded with cobalt molybdenum hydrogenation catalyst.
2. Two other reactors containing chlorine absorption catalyst and zinc oxide
Sulphur absorption catalyst.
Having passed the hydrogenation catalyst in the first reactor, the hydrogen chloride
and the hydrogen sulphide are absorbed in second and third reactors.
Reforming section: The gas from the final desulphurization section s mixed with
steam and sent to the reforming section where hydrocarbons and steam react over
the Topse Nickel reforming catalyst.
CO - conversion:
CO + H₂O -> CO₂ + H₂ + Heat
The shift reaction taking place in the MT shift converter proceeds to very close to
equilibrium. CO is converted to CO₂ by water shift reaction.

7. Amine Recovery Unit

There are three amine regeneration units in the DHDS block. They cater to the
needs of RFCCU, DHDS, FOB, LOB and OHCU units. The rich amine from
various amine absorbers is stripped off H2S by using medium pressure steam in a
regeneration column. The lean amine obtained from the bottom of regeneration
column is cooled and recycled back to amine absorbers. Absorbent used is di-
ethanol amine.

8. Sour Water Stripper

Demineralized water is used as wash water in condensers of RFCCU, DHDS,
MSQU, OHCU to prevent salt deposition and resultant corrosion inside them. This
water dissolves salts, some amount of H2S and NH3. This water is called sour
water. Sour water has to be treated to remove H2S and ammonia before being sent
to ETP for recycle. The sour water is stripped off the salts, H2S and ammonia by
stripping steam. Treated water is used as make-up water or sent to ETP.
 Bitumen Filling Station (BFS) (Unit – 36)
 Bitumen is a common binder used in road construction. It’s residual product in refinery
after higher fractions like gas, petrol, kerosene and diesel etc. are removed.
 Bitumen is produced from Asphaltene which is bottom product of Propane De-
Asphalting unit where Vacuum Residue is feed.
The Bitumen are designated by the penetration number. Penetration number is
defined as the number of units of 1/10 mm, a standard needle with 100gms load
penetration into the asphalt mass in 5 minutes of a standard test temperature. Thus a
80/100 bitumen means that the quantity of penetration is between 8 and 10 mm.

 Characteristics of bitumen:
Bitumen is a black or dark brown non-crystalline soil or viscous material having adhesive
properties derived from petroleum crude by refinery processes.

 General uses of Bitumen:

1) Construction of roads, platforms and runways.

2) Water proofing to prevent water seepage.
3) Ceramics, Canal lining to prevent erosion etc.
4) In battery manufacture as sealing compound.
5) Electrical capacitors.
6) Paint industries for manufacturing black paints and anti-corrosive paints.

OPERATING DATA:
Inlet temperature of bitumen-180+2ºC Outlet temperature of bitumen-180+3ºC
Maximum flow rate of bitumen- 36MT/H Minimum flow rate of bitumen-16
MT/H Bitumen inlet pressure to system -16ATA Bitumen outlet pressure to
system-8ATA

Production of Bitumen:

The bottom product of crude i.e. RCO (Reduced Crude Oil) is taken to a vacuum
distillation unit where distillate lube is extracted. The bottom product obtain is SR
(Short residue) which is mixed with solvent propane. Then it‟s taken to a de-
asphalting unit where the asphalt is taken out which is black and hard having less
penetration (2-10). There is a mixture of asphalt, SR and lube extract. There are
three grades of bitumen:

1. 80/100
2. 60/70
3. 30/40
These are done based on penetration property. A needle with the help of a reference
weight is introduced inside the bitumen, and it dips the least amount for30/40 and
most for 80/100.The temperature of bitumen produced it around 140˚C. Its
temperature is later brought down in the BCU (bitumen cooing unit).

BITUMEN COOLING PROCESS:

Bitumen is cooled in bitumen coolers by partial vaporization of DM water.

Steam/DM water is separated in stream drum. DM water is feed back into bitumen
coolers and steam is condensed in condensers. Units are located such the
circulation of DM water in the system is by gravity. Steam pressure in the stem
drum is maintained 0.5642 kg/cm² (abs).

BITUMEN CIRCUIT:

Bitumen flows through 3 vertical shells of 48E01A/B/C in series. Inlet line is 4inch
and inters connecting lines between cooler is8 inch with provision of pressure
gauge and temperature gauge. Bitumen outlet line from the system is also 8 inch
and makes a goose heek before final exit to ensure flooding of 8E01A/B/C.
Bitumen bypass lines are also provided across each bitumen cooler 2inch diameter
flushing oil lines are also connected in bitumen lines steam lose also can be
connected to coolers /lines by provisions made.

DM WATER CIRCUIT: Operating pressure of stream drum is 0.542 kg/cm²

(abs) steam drum is located above bitumen cooler to ensure high rate parallel
circulation of DM water through tube side of bitumen cooler via 3inch line.
Maximum DM water level in steam drum is controlled by funnel located 70mm
above center line of steam drum with discharge seal pad

48B02 where water level is to maintained for maintaining vacuum steam from
condensate flow black drum via 2 inch line.

Bitumen filling station:

Operation:

DRUM FILLING

Weight of dry drum = 8 kg. (Approximate.)

Weight of filled drum = 156.5 kg. (Approximate.)

Empty drum is unloaded from truck and taken to a filling system by belt
conveyers. The part consists of a pipeline through which the bitumen flows to the
drum and twin arm and jack system to hold the drum upward for good contact with
the filling tube. The mouth of the filled drum is sealed using a cap using air
pressure. It‟s then taken to digester where at a time 16 drums are digested (8 on
each side). The fork lifter then takes the drum and stacked at a place. Then they are
dispatch to different places by truck or railway wagon.
 Effluent Treatment Plant (ETP)
The principal objective is to treat wastewater (effluent) and dispose it without
danger to human health or unacceptable damage to the natural environment. It may
be done by extracting pollutants, remove toxicants, neutralize coarse particles, kill
pathogens so that quality of discharged water is improved to reach the allowable
level of water to be discharged into water bodies.

Refineries are among the major consumers of water to cooling towers and process
water/steam in major operations like distillation, stripping etc. During the
treatment and refining of crude oil, large amount of wastewater is generated which
needs treatment.

The principle aim of ETP of Haldia Refinery is to obtain water which is recyclable
for numerous purposes in the plant and also to make it safe for discharging in the
outside environment. The effluent consisting of oil and water, is treated via a series
of unit operation mainly clarification and continuous settling. Effective chemicals
and biological treatment are also done to render flocculation, lowering BOD and
COD of the water. These treatments have been described in the upcoming section.

PROCESS DESCRIPTION:

Feed from the effluent of FOB, LOB, OMS to OLD ETP

Feed from the effluent of DHDS, OHCU/ DYII to NEW ETP

The steps in waste water treatment are as follows:

a) Physical treatment
b) Biological treatment
c) Chemical treatment

Block diagram for EFT

PHYSICAL TREATMENT:

Objective: Physical separation of large sized contaminants.

Waste water of refinery contains coarse suspended and floating solids, oils, settle
able pollutants. These need to be removed before the waste water is subjected to
chemical and biological treatment. By physical treatment the pollutants are
removed. Rakes and screens, grinder, grid chamber, grease traps, flocculation,
sedimentation, sludge pumping etc. are common physical treatment operation in
Haldia Refinery, bar screen, wire mesh, and API separator are used for purpose for
physical treatment. Effluent is first admitted through the bar screen and wire mesh
where debris, rag are removed and then sent through grid chamber to settle out
suspended solids. The purpose of these two equipment is to protect channels. The
waste water with free oil and sludge is then routed through the API separator and
then the primary sedimentation equipment. Here the velocity of the equipment of

higher density are made to settle down and the oil of low density floats. In API
around 50% to 60% of suspended solids are removed and 20% to 40% of the BOD
at 20°C is achieved.

The physical separation occurs in the first 4 vessels:

1. Influent sump
Here all the effluent is brought and dumped and allowed to cool if feed is
hot.

2. Holding tank
Here sedimentation takes place in 3 different layers due to difference in
gravity of

 At the top floating oil layer is formed, which is separated.

  The second layer is of contaminated effluent.
 The bottom layer is of dust particles and sediments.

3. API/TPI
In IOCL Haldia refinery two ETP plants are there:

 In old ETP, API is used (American Petroleum Institute)

 In new ETP, TPI (Tilted Plate Interceptor) is used.

API or TPI separators are predominantly used in separation of free oil from
effluent water or suspended solids for oily water treatment in an oil water system
(OWS)

The basic principle of difference in gravity between the phases (liquid-liquid or

solid-liquid) is employed in an OWS in separation of two phase. This phenomena
is often called “gravity separation”.

API

API separator is a gravity separation device designed using stoke‟s law principles
that defines therise velocity of oil droplets based on their density, size and water
properties. Most of the suspended solids will settle to th bottom as a sediment
layer, the oil will rise to the top of the separator, and the waste water will be the
middle layer between the oil at top and solids at bottom. Further treatment of
wastewater is required after API. Secondary treatment technologies include
Dissolved air flotation(DAF), Anaerobic and Aerobic biological treatment etc.
TPI

TPI is also based on stokes law principle, but includes inclined plate assemblies.
The underside of each parallel plate provides more surface area for suspended oil
droplets coalesce. In operation it is intended that sediment will slide down the
topside of each parallel plate.
 4. Equilization pond:
Here the remaining separable floating layer is separated.

CHEMICAL TREATMENT:

The Chemical treatment followed by physical treatment reduces colloidal solids,

inorganic chemicals, some portion of organic chemicals and the remaining
suspended solids of the effluent.

The Chemical treatment occurs in the next two systems:

1. Flash mixture and flocculator

2. DAF (dissolved air floatation) system
Important unit operation and processes which are used for this purpose are:

i) Chemical coagulation, flocculation and sedimentation

ii) Filtration
iii) Ion exchange
iv) Reverse osmosis
v) Carbon adsorption
In Haldia refinery method number (I) along with oxidation of chemical both
organic and inorganic (especially sulphide and phenolic compound) by chlorine is
followed. Coagulation is the process in which chemicals which is termed as
coagulants are added to an aqueous system to create rapidly settling aggregate out
of present. Flocculation is the second stage in the formation of this aggregate
which is achieved by gentle and prolonged mixing. Over here coagulation occurs
in pre aeration chamber. FeSO4 solution and lime solution are added in pre
aeration chamber. Positively charged iron ions neutralize the negative ion of
emulsified oil and hence releases the oil from water. These iron ions are
hydrolyzed by hydroxides to form Fe (OH)2 FLOC's.

Dissolved O2 in the effluent oxidizes Fe(OH)2 to Fe(OH)3 floc which settles at

faster rate than Few(OH)2. For highest efficiency a rapid and intimate mixing of
Fe(OH)3 / Fe(OH)2 flocs with effluent is necessary before flocculation process
begins, which is done in flash mixer where a motor driven stirrer is rotating
continuously.

Flocs so formed are too light to settle under gravity, thus from the flash mixer
chamber the effluent goes to clariflocculator where slow stirring is done by two
continuously rotating motor driven stirrer thus enabling flocculation i.e.
agglomeration of small flocs.
BIOLOGICAL TREATMENT:

The biological treatment occurs in the bio towers.

After physical and chemical treatment waste water is brought to biological

treatment under aerobic condition for further reduction of organic pollutant. The
principle involved is to utilize naturally occurring bacteria to eat away or oxidize
organic impurities thereby reducing the concentration of pollutants. These bacteria
simultaneously get biodegraded. The excess of bacteria is removed from the
system periodically. The basic biochemical reaction for the stabilization of organic
impurities under aerobic composition by micro-organism in waste water.

Organic impurities + microbes + O2 = A more microbe + CO2+H2O + waste

energy

The common system for biological treatment is 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 the 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 is continuously fixed with waste water
and aerated by motor operated aerators. Here also bacteria eat away impurities.
The bacteria water 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.

In case of Trickling filter (bio filter) system, waste water is sprayed on the 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 fixed with waste
water and aerated by motor operated aerators. Here also bacteria eat away
impurities. The bacteria water 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.

Treated effluent standard for Petroleum Refineries:

Parameter Standard
PH 6-8.5
Phenol 0.35 ppm
Sulphide 0.5
Oil 5 ppm
 TSS 20 ppm
COD 125 ppm
BOD5 15 ppm
CN 0.2 ppm

Benefits of ETP:

 To preserve natural environment against pollution.

 To reduce the usages of fresh water in operations.
 To meet the standards for the emission of pollutants set by the government
and avoid heavy penalty.
 To reduce expenditure on water acquisition.

 To clean industrial effluent and recycle it for further use.

 OIL MOVEMENT AND STORAGE (OM&S)
This unit plays an important role in the storage of imported crude brought by
tankers. Refinery storage tanks are used in storage of crude oil and finished
petroleum products. Products from these storage tanks are dispatch for marketing
by tankers, wagon, drums, cylinders etc. The major problems with moving this oil
are pollution and chances of being spilled. Petroleum oil is very hard to clean up
and is very toxic to living animals.

The mode of dispatch depends on the distance to be traversed and on the capacity
of the pump. For the pumping of highly viscous oils, positive displacement type
pump is used where as in the case of non-viscous oil centrifugal pump are used.

About 95% of the cost involved in running a refinery is used for purchasing and
transporting crude. So, to maximise profit either we need to decrease it. Pipeline
transportation is effective means for dispatch of products. Kerosene is the
intermediate product transported between two different batches of product. Mixing
occurs but within the manufacturing specifications.
The four major ways of transportation are:

1) Pipeline: The most commonly used form of transportation is through

pipelines. They are typically used to move crude oil from the wellhead to
gathering and processing facilities and from there to refineries and tanker
loading facilities. Pipelines require significantly less energy to operate than
trucks or rail and have lower carbon footprint
2) Rail/ Wagon: The relatively small capital costs and construction period
make rail transport an ideal alternative to pipelines for long distance
shipping. However, speed, carbon emission and accidents are some
significant drawbacks to rail transport.
3) Truck: While the most limited oil transportation method in terms of storage
capacity, trucks have the greatest flexibility in potential destination. Trucks
are often the last step in the transport process, delivering oil and refined
petroleum products to their intended storage destinations.
4) Ship: Where transport over land is not suitable, oil can be transported by
ship. The drawbacks are typically speed and environmental concerns.

Various petroleum products are stored in above surface tanks. It will be there until
ready for transportation.

Tanks: Almost ⅓ of the refinery area is allocated for different types of tanks. They
are designed according to the needs of the product conservation like in the case of
MS, SRN there must be a provision to reduce the pressure produced due to the
vaporization of these products and hence these are generally stored in floating roof
tanks. By design they are four types:

1. Fixed roof tank

2. Floating roof tank
3. Fixed cum floating roof tank
4. Doom type tank

Depending on the service the tanks are provided with:

a) Sampling device
b) Temperature gauge
c) Jet mixing nozzle
d) Inert gas blanketing
e) Steam heating coils

Product is taken to this tank though the inlet by different pumps. There are two
outlet one for blending and product conveying and another for drainage. Generally,
products from different units also contain some amount of water with them. This
unwanted water is drained through that outlet. Some other important operation
such as blending is also done by the outlets. In blending different oil are mixed up
to meet the specifications of the final product oils such as Motor Speed Oils (MS),
Diesel etc. Constant circulation of the product of tank is done for better mixing
through these outlets.
Although several other designs are also made according to the need‟s tanks are
provided with:

a) Manhole on the shell and roof

b) Product inlet and outlet nozzle
c) Drains
d) Staircase and ladder
e) Mechanical type level gauge
f) Open vane with wire mesh or Breather valve or vent with flame arrester
 ONCE THROUGH HYDROCRACKER UNIT
:(OHCU)
This bock consists of following unit:
1: OHCU (once through hydrocracker unit )
2: HGU (hydrogen generation unit)
3: NGU (nitrogen generation unit )
OHCU-(ONCE THROUGH HYDROCRACKER UNIT)
(
PROCESS FLOW DIAGRAM

We call it once through because here unreacted product stream is not send back to
reactor,rather it is send to FCCU.

In vacuum distillation unit product that we get are high moleculer weight
compound so we need to break them in to smaller compound in order to increase
C to H ratio which in turn will increase the calorific value of fuel.
Here we break by taking help of catalyst and hydrogen.

This OHCU is different rom RFFCU in following ways:

Product :finished product in OHCU but product of RFFCU needs to process again

Cost:it is costilier than RFFCU’

In RCCU main product is petrol but in OHCU main product is diesel.

VGO consists of spindle oil, light oil, intermediate oil and heavy oil
 The products are light naphtha, heavy naphtha, kerosene, diesel and unconverted
oil.
Desired method of coking is catalytic cracking but thermal cracking is undesired so
it must be prevented because it may lead to high heat generation and temperature
runaway may result to failure of metals. In such case depressurization may be
implemented to control the situation.
Two steps are implemented:
Hydrotreating
Hydrocracking
Here the VGO is cracked and then fractionated to different fraction of product.
As hydrogen is released as a product in this cracker so hydrogenation og
product takes which lead to increase in cetane number so main product
that we get from here is diesel.
HGU-(Hydrogen generation unit)

As hydrogen is needed in various operation such as KHDS ,NHDT etc.so we need a

hydrogen generation unit to meet the requirement .BUT hydrogen is generated in CRU
But not in
Enough
Quantity.

(
The following processes occur in this unit:

FEED PRE-DESULPHURISATION:
The feed contains unsaturated components as well as high amount of organic
Sulphur. Sulphur would act as a poison for the downstream processes and needs to
be removed. The bulk of the Sulphur can be removed by conversion
(Hydrogenation) of the organic Sulphur components to H2S and subsequent
stripping. As an important side reaction Olefins are saturated. The Basic reactions
occurring in the section are as follows:
RSH + H2 RH + H2S
RCL + H2 RH + HCL
R=R + H2R-R

FEED DESULPHURISATION:
Sulphur and Chloride poison the pre-reforming and reforming catalyst in the
hydrogen unit even at very low levels. These catalyst poisons can be effectively
removed in the form of H2S and HCl by selective adsorbents (Zinc Oxide and
Aluminum Oxide respectively). The reactions involved are:
Co-Mo Catalyst:
RSH + H2 RH + H2S
Chlorine Guard:
AL2O3 + 6HCL 2ALCL3 + 3H2O
Zinc Oxide Catalyst:
ZnO + H2S  ZnS + H2

PREREFORMING AND REFORMING:

The feed in the presence of steam reacts to a mixture of methane, carbon dioxide,
carbon mono oxide and hydrogen over a nickel-based catalyst. These reactions
take place in both the pre-reformer and the reformer. The principal reactions are:
CnHm + nH2O  nCO + (1/2 m + n)H2 – Q
CO + H2O  CO2 + H2 + Q
For hydrocarbons with a carbon number(„n‟) higher than one, the equilibrium for
the first reaction at the outlet of the pre-reformer will almost be completely to the
CO side. The CO formed from these higher hydrocarbons will be partly converted
to methane. For n=1 and m=4; this reaction is referred to as the „steam methane
reforming reaction‟, the reverse reaction is generally referred to as „methanation
reaction‟.

SHIFT CONVERSION:
This reactor is operated at the lowest feasible temperature in order to optimize heat
recovery and the hydrogen generation from the feedstock. There are two
temperature levels at which the reactors are operated with the first one named as
High Temperature Shift Reactor operated at 350 0C and the other named as Low
Temperature Shift Reactor which is operated at 200 0C. The optimum operating
temperatures increase as catalyst ages.
The principle reaction is:
CO + H 2 O  CO2 + H2

PRESSURE SWING ADSORPTION (PSA):

PSA technology is used to remove the impurities from the reformed gas. This is
achieved by molecular sieves which adsorb the contaminants and allow the
hydrogen

gas to pass. To regenerate the molecular sieves, the adsorber is depressurized. This
releases the contaminants and after pressurization the adsorber is ready for reuse.
The contaminants which are released at low pressure are collected in the purge gas
drum and are used to meet part of the heat demand of the reformer.
NGU-
This is the nitrogen generation unit. Used to produce nitrogen for the plant from
atmospheric nitrogen.

Statistics:
HGU production rate: 9375 kg/Hr Crude throughput: 7800 TMT Distillation
yield:
%on crude=69
Sp. Energy consumption: 518 (MBN) Fuel and loss: % on crude =8.7 Capacity
utilization: 94.0%
Overall thermal efficiency of power plant: 84.8% Plant ability factor: 99.5%
Nitrogen unit: 2000 Nm3/hr gas
1600 Nm3/hr gas + 400 Nm3/hr equivalent liquid HGU-II : 75000
MTPA OHCU: 1.7 MMTPA
 CONCLUSION
As a part of the course curriculum, we had undergone our summer training
program at Indian Oil Corporation Limited, and would gladly say we are highly
honored and satisfied with our experience
Starting with the “heart” of the refinery, CDU and VDU, we get to know how
physical separation different products occur and various process equipment and
unit operations. We even get an insight about the products usage, their storage and
the various treatment techniques used for purification. On the other hand, from
DHDS, KHDS & SRU, we get wide knowledge of Sulphur recovery which is
much important for environmental aspects.
In today‟s world, LPG & Gasoline are important for automobile and domestic
purpose, but from CDU, we get fewer amounts of LPG and Gasoline than our
requirement. So, the RFCCU supplies the additional LPG and Gasoline
requirement
The Plant visit was the greatest achievement where we could see the industries
massive scale production using the same concepts we had read in our books.
Haldia refinery is only refinery which also takes an important role for lube oil
production and separation of aromatics wax and asphalt from lube oil is very much
important.
Overall the learning experience was memorable and we enjoyed every moment of
our stay at IOCL, Haldia Refinery. Within the limitations of official duties, we
were introduced to the concepts very well, and were guided with extreme care and
concern. Thus, we had an excellent stay, and would try our best to implement the
knowledge gathered in our future endeavors.