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Sandeep Kumar
09210011
Department of Chemical Engineering
Indian Institute of Technology Roorkee
Contents
1. PLANT LAYOUT
2. FUEL OIL BLOCK
3. LUBE OIL BLOCK
4. DHDS(Diesel hydro de-sulfurisation) BLOCK
5. REFERENCES
Plant Layout
Block Flow Diagram of Haldia Refinery
Desulphurised
Fuel Gas
Fuel Gas
ATU SRU Sulphur
LPG LPG
Naphtha
SR Naph C5 90C
FCCU
GO
SO CBFS
Ext. 70 N GR-II
V V LO / IO / HO
RCO
D D FEU SDU HFU
150 N GR-I / II
U U NMP
500 N GR-I / II
DAO S.Wax 850 N
1 2
150 BS GR-I/II
PDA
CDWU
Asp.
SR
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Crude Distillation Unit (CDU)
Feed: Arab mix (lube bearing) and Dubai (non-lube bearing) Crude oil.
Process : Separation of liquid feed mixture (crude oil) into different components on the
basis of relative volatility.
Products :
Short Name Full Name Cut Range oC Usage
Gas Fuel gas C1-C2 Internal Fuel
LPG Liquefied Petroleum Gas C3-C4 Domestic fuel gas
2. Prefractionator:
Inlet Temperature : 180 C -200 C
Top Temperature : 115 C -120 C
Top Pressure : 2.6-3.2 kg/cm2
Stripping Steam : 2500-3000 kg/hr
Flash Zone Pressure : 2.7-3.4 kg/cm2
4. Crude Heater:
Coil Inlet Temperature : 270 C
Coil Outlet Temperature : 350-370C
Radiation Skin Temp : 440 C
Operating parameters
3. Atmospheric Column:
Temp: 112-130decreases.
oC
Naptha
KERO DRAW
Too high Coil Reduced crude not as
12-18
KERO CR VS
outlet temp specification for vaccum/FCCU
Kerosene flash point becomes
Too low feed.
low LGO DRAW KERO R/D
Crude PreheatsStabilization
increases. and
19 JFGOPF
splitting
TOP CR BH
Heavy
HSD The draw off temperature, as well
B22
HSD CR
increases.
Vapor VS
HGO Draw
CR 12
Overhead condenser duty
7
LGO R/D
decreases. VS
Desalted 6 JBO Overflash
T=265oC HGO R/D
crude oil VS (Superheated steam)
RCO
Stabilization and
19
splitting
TOP CR
Heavy
Naptha
B22
KERO DRAW
12-18
KERO CR VS
HSD CR Vapor VS
12 HGO Draw
LGO R/D
7
VS
Desalted 6 JBO Overflash
T=265oC HGO R/D
crude oil VS (Superheated steam)
RCO
1. Feedstocks: It is blend of
Intermediate oil : 34%
Light oil : 31%
Heavy oil : 4%
Deasphalted oil (DAO) : 9%
Spindle oil : 22%
The unit is based on 65-75% conversion and un-converted oil will serve as a FCCU
feedstock.
Main aim of maximizing diesel, recovering LPG while minimizing Naptha, Kerosene
and fuel gas.
The unit has an objective for the 1.85 MM metric ton/year (249.5 m3/hr i.e. 112% of
design)
Monocyclic napthenes are dealkylated and then isomerized into light isoparaffins and
lower molecular weight napthenes.
Bicyclic napthenes are reacting open one ring in order to form alkyl substituted
monocyclic napthenes.
3.Coking:
The heavy aromatics (asphaltenes) are not crack able compounds and are
strongly adsorbed on the acidic sites of catalyst where they subsequently
polymerize and eventually form coke.
1.Hydrotreating catalyst:
HR 360. The metals Ni and MO need to be in their sulfied form to work in an H2S
atmosphere and to be very stable under design operating conditions. Support is an
alumina base.
2.Hydrocracking catalyst:
3. Pour Point
3.Flash Point
4. Color
5 .Oxidation Stability
LOBS (As per API) VI SULPHER % SATURATES %
PROCESS: Vacuum distillation, because boiling point reduces with decrease in pressure.
Liquid propane
1 2 dissolves the oil
JBO JBO (2 GRADES)
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Lube oil Block (LOB)
Purpose : To remove
aromatic hydrocarbons from
Block Flow Diagram of Haldia Refinery
vacuum distillates and DAO
Pressure :Fuel38 kg/cm 2
for improving VI
Desulphurised
Fuel Gas
SRUof the Sulphur
Gas
ATU
LPG
products. LPG
Temperature: 60-80 oC
SR Naph C5 90C
Naphtha
Crude
U U St.Run G.O
DHDS Furfural dissolves
HSD (2 GRADES)
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Lube oil Block (LOB)
Gauge Pressure : 1-
2kg/cm2
Block Flow Diagram of Haldia Refinery
Fuel Gas
Temperature: Top 95- Desulphurised
Fuel Gas
ATU SRU Sulphur
LPG 130 oC, Bottom 45-80 LPG
oC
Naphtha
SR Naph C5 90C
FCCU
GO
SO CBFS
Ext. 70 N GR-II
V V LO / IO / HO
RCO
D D FEU SDU HFU
150 N GR-I / II
U U NMP
500 N GR-I / II
DAO S.Wax 850 N
1 2
150 BS GR-I/II
PDA
CDWU
Asp.
SR
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Lube oil Block (LOB)
Purpose: To separate the
Block Flow Diagram of Haldia Refinery
wax from the Raffinates Desulphurised
Fuel Gas
Fuel obtained
Gas from ATU SRU Sulphur
LPG LPG
atmospheric
SR Naph C5 90C
extraction Naphtha
Units (FEUCRU
90 140C
& NMPEU) to MS( 3 GRADES)
1 2
Extraction and
JBO JBO (2 GRADES)
crystallization to achieve
FCCU
GO de-waxing. CBFS
SO
Ext. 70 N GR-II
V V LO / IO / HO
RCO
D D FEU SDU HFU
150 N GR-I / II
U U NMP
500 N GR-I / II
DAO S.Wax 850 N
1 2
150 BS GR-I/II
PDA
CDWU
Asp.
SR
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Lube oil Block (LOB)
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Lube oil Block (LOB)
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Lube oil Block (LOB)
CRU
Gauge Pressure
90 140C : 10
HGU
MS( 3 GRADES)
MTO
C C 2Kero Cut
kg/cm RTF/ATF
D D KHDS H2
Kerosene
U U St.Run G.O
DHDS
Crude HSD (2 GRADES)
Temperature:
1 2 JBO
440 oC
JBO (2 GRADES)
FCCU
Residence time: 25-30 min
GO
CBFS
SO
Ext. 70 N GR-II
V V LO / IO / HO
RCO
D D FEU SDU HFU
150 N GR-I / II
U U NMP
500 N GR-I / II
DAO S.Wax 850 N
1 2
150 BS GR-I/II
PDA
CDWU
Asp.
SR
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Lube oil Block (LOB)
Purpose : To improve the
color stability and Lube
Block Flow Diagram
stocks. of Haldia Refinery
Desulphurised
Fuel Gas
Process: The process
Fuel Gas
ATU isSRU Sulphur
LPG LPG
SR Naph C5 90C mild hydrotreating using a Naphtha
CRU
90 140C catalyst in presence of H2 MS( 3 GRADES)
HGU MTO
C C Kero Cut RTF/ATF
KHDS
D
U
D
U St.Run G.O
Produces Group 1
H
LOBS. 2 Kerosene
FCCU
GO
SO CBFS
Ext. 70 N GR-II
V V LO / IO / HO
RCO
D D FEU SDU HFU
150 N GR-I / II
U U NMP
500 N GR-I / II
DAO S.Wax 850 N
1 2
150 BS GR-I/II
PDA
CDWU
Asp.
SR
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Lube oil Block (LOB)
Crude
U U St.Run G.O
H2 flow rate: 400-450 kg/h
DHDS HSD (2 GRADES)
FCCU
GO
SO CBFS
Ext. 70 N GR-II
V V LO / IO / HO
RCO
D D FEU SDU HFU
150 N GR-I / II
U U NMP
500 N GR-I / II
DAO S.Wax 850 N
1 2
150 BS GR-I/II
PDA
CDWU
Asp.
SR
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Lube oil Block (LOB)
Purpose : It produces
Block Flow Diagram of Haldia Refinery
superior grade group 2 Desulphurised
Fuel Gas LOBS. ATU SRU
Fuel Gas
Sulphur
LPG LPG
Naphtha
SR Naph
Conversion of Wax
C5 90C
90 140C
CRU
Title to non
component HGUwaxy
MS( 3 GRADES)
MTO
C C Kero Cut
KHDS components.
RTF/ATF
D D H 2 Kerosene
U U St.Run G.O
DHDS
Crude HSD (2 GRADES)
GO
paraffins FCCU
SO CBFS
Ext. 70 N GR-II
V V LO / IO / HO
RCO
D D FEU SDU HFU
150 N GR-I / II
U U NMP
500 N GR-I / II
DAO S.Wax 850 N
1 2
150 BS GR-I/II
PDA
CDWU
Asp.
SR
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Lube oil Block (LOB)
GO
Nm3/h FCCU
SO CBFS
Ext. 70 N GR-II
V V LO / IO / HO
RCO
D D FEU SDU HFU
150 N GR-I / II
U U NMP
500 N GR-I / II
DAO S.Wax 850 N
1 2
150 BS GR-I/II
PDA
CDWU
Asp.
SR
LO MCW MCW
VBU FO (2 GRADES)
Bitumen(3GRADES)
BTU
Bit Eml.
IFO
Fluidized Catalytic Cracking Unit
1. Reactor
Temperature : 370 OC
Pressure : 1.4 kg/cm2
Regenerator Section
Temperature : 700 OC
Isomerization reactions
n- C4H10 ------------> iso- C4H10
Dehydrogenation reactions
n- C8H18 ------------> C8H16 + H2
Dealkylation
Iso C3H7-C6H5 ----------> C6H6 + C3H6
FUEL GAS
FLUE GAS TO
INCINRATOR
LPG + NAPHTHA
REACTOR
RG-2 HEAVY NAPHTHA
AIR
LCO TO
FRACTIONATOR RISER
HCO TO
RISER
RISERR
FLUE GAS TO
INCINRATOR
RG-1
AIR
SPENT
CATLYST
SLURRY TO
CATALYST
RECOVERY
FEED + STEAM