Overview of

Process Units
Overview
COT
Crude Oil
Tankage
Refinery Area
ISBL
Inside Battery Limits
Process Units
Utilities
Offsites
ETP
Interconnecting Lines
Other facilities
OSBL
Outside Battery Limits
Refinery Consists of

Jetty
ISBL
ISBL = In Side Battery Limits
Primary and Secondary processing of crude
Treatment of products
FO Blending
Off sites - All OSBL facilities handling
hydrocarbons/Utilities
Process units are arranged in different blocks
CDU
VDU
SGU
VBU
Treating
FCC
UGS
FGD
NHT
CCR
ARU
SRU
SWS
DHDS

ISBL
Crude is pumped from COT (Crude
Oil Terminal) to refinery
Crude is received at refinery in
Crude Day Tanks which are located
in PIT (Product Intermediate Tank
Farm)
PIT is located outside battery limits
and comes under off sites area.
All products are sent to PIT before
final blending and dispatch to
marketing terminals.
Utilities like cooling water, steam,
air, nitrogen etc are also OSBL
COT
PIT
Process Units


ISBL
Crude
Atmospheric
Distillation
Middle
Distillates
RCO
TO VDU
Blending
Secondary
Processing
Storage
Process Units
Naphtha
CDU - VDU
Crude
CDU
NHT
LPG LMU
KMU Kero
Gas Oils
DHDS
Vacuum
Gas Oils
FCCU
Bottoms
VBU
VDU
Vacuum
Distillate
CDU
Objective
To separate crude into different products by
boiling point differences.
Prepare feed for secondary processing units
Products
Fuel Gas Refinery Fuel System
LPG Merichem Treating LMU
Naphtha NHT and Storage
Kero / ATF Merichem Treating KMU
Light and Heavy Gas Oils DHDS
Reduced Crude Oil Vacuum Distillation VDU
Design Capacities
CDU / VDU / SGU 10.5 / 12
VBU 1.9
NHT 1.36 / 1.6
CCR 0.9
FCC / UGS 2.9 / 3.3
DHDS 3.3 / 3.7
SRU (2 Trains) 2 x 220 (TPD)
SWEETENING UNITS :

KEROSENE 0.63 x 2
GASOLINE 0.5 x 2
SAT. LPG 0.28
UNSAT. LPG 0.29 x 2
C
D
U
U
V
D
KMU
U
V
B
HSD
F
C
C
U
FO
Gasoline
SGU
LMU
LP
G
FO
Blending
DHDS
NHT
CCR
Gasolin
e
Blendin
g
Diesel
Blendin
g
UMU
GMU
KERO
ATF
Naphtha
Block Flow
Atmospheric Distillation Process
16000 M3X2
Desalter-I
Desalter-II

Preflash
Off Gas / Ovhd Naphtha - SGU
Heavy Naphtha -NHT
L Kero - KMU,FO
H Kero - KMU, FO
LGO -DHDS, FO
HGO - DHDS, FO
RCO to VDU
364
0
C
280
0
C
20
0
C
20kg/cm
2
g
123
0
C
133
0
C
11kg/cm
2
g
CDU Schematic
Vacuum Distillation
Atmospheric Distillation bottom
is sent for Vacuum Distillation.
Distillation under vacuum aids in
separation at lower
temperatures.
Hence lower cracking and
resultant coking/ fouling of
equipment

Vacuum Column
50 m
6.8 m
12.5 m
8.2 m
Feed
Flash Zone -
vane type
inlet
Stripping
Section
Chimney
Tray
Bed 4
Steam
Valve
Trays
VDU Products
Vacuum Distillate
FEED
LVGO
HVGO
HHVGO
VR
Ejectors and
Vacuum Pump
BED-1
BED-2
BED-3
BED-4
Reflux
Air Cooled TPA
HVGO - PA
HVGO - Reflux
Fired Heaters
Fired Heaters are integral part of
refinery
Used for heating of process fluids
Fuel Oil / Fuel gas is produced
during refining operation and
utilized here
Superheating of steam
Operated with advance process
control features
Air
Filter
ID Fan
Fired Heater Schematic
FD Fan
FD Fan
CS APH
Glass APH
F-151 A
Stack
Damper
By pass
across
GAPH
PC
Hydraulic Coupling
regulated speed
TC

VBU
VISBREAKER UNIT - 20
LICENSOR - AXENS (IFP)
Naphtha
Visbreaker
Visbreaker
NHT
Off Gases
UGS
Vac Gas Oils FCCU
Slurry Oil
FO
Blending
Gas Oils DHDS VR
Visbreaker Unit
PURPOSE:
Production of additional light products by mild
thermal cracking of Vacuum Residue
Changing high viscosity heavy cuts into lighter
fractions.
Capacity
4919 MT/ SD for case 1 : 70/30 AL/AH Crudes
5782 MT/SD for case 2 : 50/50 wt% AL/AH Crudes
Turn down - 60 % of case 2 capacity
VBU also has a Fuel Oil Blending Station for
High Sulfur Fuel Oil production
Plant Fuel Oil production
VBU - Atmospheric Column
Valve type trays
for Fractionation

TL-TL - 30.65 m
Diameter
TOP - 1.9 m
Middle - 3.2 m
Bottom - 1.9 m
Shower
Deck type
trays for
washing
1
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
24
25
26
27 Flash Zone
Chimney
tray
Advantages of
Valve Trays:
Uniform vapor
distribution
wide operating
range
Higher capacity
low pressure
drop
VBU Schematic
Feed/VVR
FC
Vacuum Column VGO and Bottom
PFO
Export FO
Tempered
Water
Cooler
LP Steam
Generator
MP Steam
Generator
FC
VGO
LP Steam
Generator
LP Steam
Generator
FCC/Storag
e
VGO PA
200
0
C
80
0
C
180
0
C
355
0
C
255
0
C
250
0
C
180
0
C
1
8
9
10
11
12
13
14
15
16
17
18
19
20
21
23
24
25
26
27
Naphtha - To Stabilizer
AGO to DHDS
Off Gases - to UGS / FCCU
Bottoms To Vacuum Column
To NHT
Top VGO
VGO
VFR
Visbreaker Products Overview
LC
VBU-Vacuum Column
LP Steam
Vacuum Column
Diameter
Upper - 2.5 m
Lower - 3.8 m
Length
TL-TL - 31.8 m
Packed Beds
Shower Deck
Pressure
TOP - 60 mm Hg a
Bot - 70 mm Hg a
Temperature
TOP - 70
0
C
Bot - 388
0
C
FCCU
FLUIDIZED BED
CATALYTIC
CRACKING UNIT
FCCU
Naphtha
FCCU
FCCU
GMU
LPG
UMU
Gas Oils DHDS
Slurry Oil
FO
Blending
Vacuum
Gas Oils
VDU
Bottoms
Visbreaker
Introduction:
Cracking: Breaking of heavier molecules
C-C-CC-C-C-C-C-C --->C-C-C-C + C-C-C + C-C ----

Objective of Cracking
To convert heavy petroleum fractions into useful light
petroleum products.

Types of Cracking
1. Thermal Cracking ( High Temperature )
2. Catalytic Cracking ( Low Temperature )
3. Hydrocracking ( High Pressure )
FCCU

Licensor : STONE & WEBSTER

Capacity : 8798 MT/SD (2.93 MMTPA)

On stream : 8000 hours per year

Crude source : 70/30 Arab light/Arab heavy crude

Feedstock : A mixture of following streams:
LVGO, HVGO, HHVGO from VDU
VVGO from VBU
IBP-320 C FBP-670C

Objective : Maximum LPG, Gasoline& Diesel

Products : Fuel Gas, LPG, Gasoline, HSD,FO
EOL -FCCU
FCCU
NHT /CCR
NAPHTHA HYDROTREATER


CONTINUOUS CATALYTIC
CRACKING UNIT
NHT
Licensor :Axens (IFP, France)
Capacity :1.36 MMTPA.
Purpose : To Prepare feed for CCR unit
Feedstock:
Naphtha from CDU,
FCC Gasoline,
VBU Naphtha, DHDS Naphtha
Product :
Hydrotreated Hy. Naphtha to CCR
Light Naphtha to Storage

KO Drum
Air Fin
F
E
E
D

N
A
P

Treatment
65
0
C
254 - 315
0
C
280-340
0
C
Recycle H
2

Recycle
Comp

Make up H
2

BFW
Purge
17 bar
28 bar
79
0
C
Air Fin
Air Fin

195
0
C
Purge
32 C 001
Stripper
Corrosion
Inhibitor
Air Fin

Flare
32 C 002
Splitter
HH
naphtha
to CRU
NHT Schematic
Hydrotreated
naphtha to
STG
NHT Schematic
CCR Unit
Licensor : Axens (IFP, France)
Capacity : 0.9 MMTPA
Turndown : 50%
Purpose : To Produce high octane reformate
Feedstock: Hydrotreated Naphtha from NHT
Product : High Octane reformate
Hydrogen
LPG
CCR Reactors
CCR Schematic
DHDS
Diesel
Hydro Desulpherizer
(DHDS)
DHDS
Licensor :Axens (IFP, France)
Capacity :3.3 MMTPA
Purpose
To produce desulphurized gasoil with improved
cetane quality and low sulfur
Feedstock:
HK, LGO, HGO, VD from CDU/VDU,
LCO from FCC and
VB gasoil from VBU
Product:
Desulphurized gasoil and wild naphtha.

DHDS Schematic
Sulfur Recovery Unit
S R U
SRU
Objective
The main objective of this unit is to convert H
2
S
present in acid gases of the refinery to elemental
sulphur and thereby avoid pollution of the
environment while recovering the sulfur for other
uses.
Capacity of SRU
440 MT/SD (Two train each of 220 MT/SD)

Typical Schematic SRU - Clause Process