1

A
TRAINING REPORT ON
INDIAN OIL CORPORATION LTD.
HALDIA REFINERY

DURATION - June 03, 2014 June 30, 2014.

PREPARED AND SUBMITTED BY:-
ANUPAM SRIVASTAV

INSTITUTION: -
BUNDELKHAND INSTITUTE OF ENGINEERING AND
TECHNOLOGY, JHANSI.
DEPARTMENT OF CHEMICAL ENGINEERING.





2
Contents

Acknowledgement 04
Person to Whom Reported 05
Preface 06
Plant Overview 07
Haldia Refinery Product 08
Fuel Oil Block 10
DHDS Block 19
Once Through Hydrocracker Unit Block 40
Lube Oil Block 50
Oil Movement and Storage Block 69
Conclusion 80



3
ACKNOWLEDGEMENTS
We would like to express our heartfelt gratitude to the Training and Placement
cell of Bundelkhand Institute of Engineering and Technology, Jhansi and Indian
oil corporation Ltd, Haldia management for providing us with the opportunity to
undertake our in plant Industrial Training in one of the most technically
advanced and reputed refinery in India.
We would like to personally thank:
Mrs Mohua Basu,
Mr Amal Bikas Das,
Mr Sandeep Lahiri,
Mr Shantanu Kumar Sarkar,
Mr K.C.Mukherjee,
Mr P.K. Mandal,
Mr A. Mukherjee,
Mr Lallan Kumar Paul,
Mr D.P. Chakraborty
And all the members of I.O.C.L. of Haldia refinery for making our training
successfully.
We would also like to thank all our respected and dear friends without whom
guidance and help it would not have been possible for us to be successful in our
training.
Date: June 30, 2014.
Place: I.O.C.L. Haldia.





4

PERSONS TO WHOM REPORTED

Referred to :
Shri. Shantanu Kumar Sarkar (CPNM):-
Shri S. Lahiri (CPNM):-



Signature
A. B. Das
SO (MS, T&D)
NAME OF AREA I/C SIGNATURE OF AREA I/C
Fuel Oil Block:
Shri A. Mukherjee(SPNM)/Shri P.
Choudhury(PNM )

Diesel Hydro De Sulphurisation Unit:
Shri P. Adhikary (PNM)/Shri P.K
Mandal(DPNM)

Once through Hydro Cracker Unit:
Shri K.C Mukherjee (SPNM)

Lube Oil Block:
Shri L.K Paul (PNM)

Oil Movement & Storage Block:
Shri D.P. Chakraborty(PNM)



5
PREFACE
This report is based on the project dissertation in I.O.C.L. Haldia I.O.C.L is one
of the most advanced plant in India for oil refining. I.O.C.L has been using
American, Japanese & Russian technology. The raw material that is used in
plant is also imported from Arabian countries, transported by ship. Haldia
refinery was initially lube oil based refinery. Total production capacity of plant
is 7.6 MMTPA.
This report is organised with various types of pressure, temperature, flow &
Level measuring instruments & also D.C.S & P.L.C.
This report is in a sequence of unit overview process instruments, D.C.S &
P.L.C.
IOCL is the only Indian company, which is prestigious list of Fortune 500.
IOCL stared its journey way back in 1959 Indian oil company Ltd. It became
Indian Oil Corporation limited in 1964. There are 7 refining running under
IOCL and another one is under commissioning at Paradip.
The seven refineries are as follows:
1. AOD, Digboi
2. Guwahati
3. Haldia
4. Mathura
5. Barauni
6. Vadodara
7. Panipat
Uniqueness of Haldia Refinery:
1. One of the Indias three lube oil refineries producing high grade lube base
feed stocks.
2. Incorporating 70% indigenous equipments for the first time in India.
3. Indias only refinery producing Bright stock-a lube oil base stock for
making lube oil which is used in heavy duty equipment.
4. First Indian refinery to receive ISO-9002 certificate.
PLANT OVERVIEW
The refinery manufactures fuel products & HVI grade lube oil base stocks.


6
The refinery has the following units:
FOB(Fuel oil block)
LOB(Lube oil block)
DHDS(Diesel hydro desulphurization unit)
OHCU(Once through hydrocracker unit)
OM & S(Oil movement and storage)
TPS(Thermal power station)
Workshop
Quality control and Laboratory
ETP(Effluent treatment plant)
MIS(Management information system)
Training centre
IMA(Indian oil management academy at Township)
FOB compromises of following units:-
1. Crude Distillation unit(CDU-1,CDU-2)
2. NAHDT
3. Catalytic reforming unit(CRU)
4. Kerosene Hydro Desulphurization unit(KHDS)
LOB comprises of the following units:-
1. Vacuum Distillation Unit(VDU)
2. Propane De Asphalting Unit(PDU)
3. Furfural Extraction Unit(FEU)
4. Solvent De Waxing Unit (SDU)
5. Lube Hydro Finishing Unit(LHFU)
6. Bitumen Treating Unit(BTU)
7. Vis Breaker Unit((VBU)
8. Micro Crystal Wax(MCW)
9. Nitro Methyl Pyrolidyne(NPM)
DHDS comprises of following main units:-
1. Hydro generation unit
2. DHDS
3. Sulphur Recovery unit(SRU)
4. Amine Regeneration Unit(ARU)


7
5. RFCCU(Regeneration fluidised Catalytic Cracking Unit)
6. MSQL(Motor Spirit Quality Up gradation)
OHCU comprises of following Unit:-
1. Hydro Cracker
2. Hydrogen Generation Unit
3. Nitrogen generation Unit
OM &S is subdivided into following sections for operating convenience:-
1. Crude tanker unloading
2. Crude tank farm
3. LPG storage
4. LPG bottling plant
5. Tank wagon loading
6. Tank truck loading
7. Bitumen filling station drum and pack
8. Solvent tank firm

HALDIA REFINERY PRODUCTS

1. Liquefied petroleum Gas(LPG)
2. Straight run naphtha(SRN)
3. Motor spirit(MS)
4. Bitumen
5. Superior Kerosene oil
6. Aviation Turbine Fuel(ATF)
7. Russian Turbine Fuel(RTF)
8. Mineral Turpentine oil(MTO)
9. High speed diesel(HSD)
10. Jute Batching Oil (JBO)
11. Light Neutral Lube oil base stock (LN-LOBS)
12. Bright Neutral Lube oil base stock (BN-LOBS)
13. Fuel gas
14. Slack wax inters neutral (IN-SW)
15. Slack wax Bright neutral (BN-SW)


8
16. Carbon block feed stock (CBFS)
17. IOC process oil

























9
FUEL OIL BLOCK
CRUDE DISTILLATION UNIT

INTRODUCTION:-
The crude distillation unit at Haldia Refinery was designed for processing of 2.5
MMTPA of Agajhari crude with a processing rate of 7500 MT per day
considering 8000 on stream hrs. per Annum. The unit was debottlenecked in
Dec84 to 2.75 MMTPA by minor modifications. After that trays and column
internals replacement was undertaken in May88 with the help of M/S EIL to
suit the column to process 3.16 MMTPA.
Subsequently a prefractionator column was installed in May96. With the
addition of the prefractionator the capacity of CDU has increased to 10500
MT/Day of upper Zakum or Arab mix crude which is equivalent to 3.5 MMTPA
considering 8000 stream hours per year.
Crude distillation (Unit No 11) includes
Pre fractionator section
Topping section
Naphtha Stabilizer
Naphtha Redistillation
Gas plant (Unit No 12) includes
De-ethaniser
Amine washing of LPG
Depropaniser
Amine Absorption & Regeneration unit (unit no.15)
Fuel Gas Amine Absorption system
Amine(DEA) Regeneration





10
PRINCIPLE OF OPERATION
Crude oil is heated to 120 1300C in the first set of pre heat exchanger
before feeding to the Desalter.Crude is desalted to the extent of 95% in
the Desalter. Crude is there after heated to approximately 180-200 C in
the second set of heat exchangers and pretopped in the Prefractionator
column to get overhead gasoline from the top(IBP-140) and pretopped
crude from the bottom of the column. Again crude is heated to 260-265 C
in the third set of exchangers and 350-360 in the furnace. The crude oil is
then fractionated in the atmospheric distillation column (11C01) to obtain
the following streams.
Refining of overhead (IBP-140C cut)
a) IBP-140 C cut is fractionated in stabilization column into two products.
Very low boiling hydrocarbon portion upto BUTANE/BUTENE is
obtained from overhead and routed to gas plant.
C5-140 cut is obtained from bottom and routed to Naphtha
Redistillation column.
b) Gas plant stabilizer overhead product is first distilled in De-ethaniser for
separation of ethane. 12C01 overhead stream, rich in ethane, is sent to
fuel gas system of refining. De-ethaniser bottom is Amine washed in
column 12C02 for removal of H
2
S and then routed to Merox(unit-13) for
mercaptan removal. Crudes presently being processed contain low H
2
S in
LPG range and Amine washing is not required. Hence the column 12C02
is by-passed.
c) Merox Treatment: LPG from Gas plant is caustic washed and then sent to
LPG extractor (13C01) where it comes in counter current contact with
Merox catalyst dispersed in caustic solution. Mercaptan free raffinate
LPG, after caustic separation is sent to LPG storage.
d) Propane production: A part of Merox treated LPG is fractionated in De-
propaniser column of gas plant to produce PROPANE of around 8-10
MT/Day depending on its requirement at Propane deasphalting unit in
Lube oil block.
e) Spiliting of C5-140 C cut:
In Naphtha Redistillation column C5-140 C portion is fractionated into
C5-90 and 90 to 140 C cut, i.e light naphtha and heavy naphtha.
f) Kerosene/ ATF/ MTO/ RTF
g) Gas oil


11
CATALYTIC REFORMING UNIT
INTRODUCTION
The operating manual describes all necessary procedures for the start-up,
stable& safe operation and shut down of the CRU (Catalytic Reforming
Unit). The unit was built by M/S Technip using a process licensed jointly
by Indian Institute of Petroleum, India and Institute Francias du petrole,
France for processing 196 TMT of Naphtha with a stream factor of 8200
hours.

In August-Sept 2005 a major revamp was carried out, with process
licensed by M/S Axens of France, to increase capacity, enhance product
quality.
In June-May 12 M & I was carried out with the complete replacement of
catalyst with UOP platforming catalyst to meet Euro-IV requirements.
This manual has been made in pretext of CRU12 catalyst replacement.
The purpose of the catalytic reforming unit is to improve octane number
of hydro treated gasoline, producing a total reformate cut(min.RONC 97)
with minimum guaranteed yield of 84.4 wt% (SOR) and 83.3 wt% at
EOR with reformate of 0.60 kg/cm
2
RVP and hydrogen rich gas. The
unit capacity after 2005 revamp was 216 MT/Yr, with an on stream factor
of 800 hours. In the revamp, the first old axial reactor has been removed
and a new radial reactor has been put on service as third reactor. Also, the
second old interheater has been removed and a new heater put on service
as a first interheater.

BATTERY LIMIT AREA:

PROCESS DESCRIPTION:



12
Preheat section:
Naphtha distillate from storage tank is fed by pump to magnetic filter,
where the metallic particles are removed. The foreign material present in
the feed are separated out and fouling in the preheat exchanger is
reduced. Then it is mixed with H
2
, make up gas from reforming unit and
recycle gas discharge by compressor and is heated to about 360
0
c in a
preheat exchanger(packinox Exchanger)
In the shell side where it is heated by hot reactor effluent.

Furnance and Reaction Sections
Completely vaporised naphtha and gases, after passing through the first
furnance is heated to the reaction temperature , enter at the top of the first
down flow peactor.
Operating pressure = 27.3 kg/cm
2
g
Operating temperature =512
0
C
The reactor is filled with a bimettalic platinum rhenium catalyst support
on very high purity alumina. When the feed come in contact with catalyst
reforming reaction take place .due to endothermicity of reaction, the
temperature of reactant decreases. The effluent from the first reactor is
therefore, reheated in a second furnance to make up the loss of heat in the
first reactor.
Operating condition for the second reactor:
Operating pressure =26.3kg/cm
2

Operating temperature = 512
0
C
Reheated effluent is then passed through the second reactor containing
platinum rhenium catalyst where further reforming reactions take
place.Effluent from the second reactor is again reheated in furnace and
passed through reactor containing the catalyst to complete the reforming
reactions for obtaining the product with desired octane number.
Reactor effluent cooling system
The effluent from reactor is cooled and partially condensed in a
series of exchangers as follows.
In the tube side of exchanger to preheat feed and to reboil stripper
bottoms


13
In the packinnox exchanger to preheat feed
In shell side of the water cooler
The effluent thereafter is sent to the separator drum.

Separator Drum and recycled Gas section
The reactor effluent is split into gaseous and liquid phases in separator
drum.
The liquid phase is sent to stripper column
Apart of gaseous phase is recycled as recycle gas within CRU
Another part is sent to make up to Naptha Pretreatment section
Remaining to KHDS section
The hydrogen rich gas from the separator drum is recycled by means of
the centrifugal compressor. Part of the compressed gas is mixed with the
preheated naptha as described earlier.

Stabilizer section
The liquid from the separator drum is fed to the stabilizer . The liquid
is reheated in the shell side of the exchangers with the stabilizer bottom
product on the tube side and the enters the stablizer .
A part of the stabilizer bottom product is reboiled in thermosyphon type
exchanger.
The stabilizer overhead vapours are cooled and partially condensed by
condenser and are collected in the overhead horizontal reflux drum.
The stabilizer bottom part is passed through exchangers and cooler before
it is sent to storage and feed to reformer splitter.
The top product from the stabilizer is sent to reflux drum where the gas
stream is separated from the top of the drum and sent to fuel gas or
M.S.Q.U unit . Apart of the liquid is pumped back into the stripper while
the other consist of LPG to rundown.




14
KERO HYDRO DE SULPHURISATION UNIT (KHDS)
INTRODUCTION:
This describes all the necessary procedures for the start-up, operation and
shut down of 577,500 TPA Kerosene Hydro Desulphurisation Unit.
Installation of mounted APH with FD fans and replacement of existing
natural draft burners with forced draft low NOx and low excess air
burners in KHDS furnace has not only increased the overall efficiency of
the furnace but also net savings in terms of capital cost by removing FO
consumption in the furnace. This unit was built by TECHNIP and it uses
a process licence jointly developed by Indian Institute of Petroleum and
Institute Francis Du Petrole, France.
UNIT CAPACITY:
The Kero Hydro De Sulphurisation unit is designed for 577,500 tons per
year capacity with 8200 on stream hours.
PROCESS DESCRIPTION:
FEED AND GAS PRE HEATING SECTION
Raw Kerosene/MTO/ATF feed from the storage is taken to the unit
through 23 FCV 01 by a pump 23 P OI A/B. The feed is subsequently
mixed with recycle gas available from discharge of the compressor 23 K
01 A/B/K-101A which is taken as make up hydrogen to its suction ex
CRU/DHDS. Both, liquid feed and gas streams are heated in heat
exchangers 23 E 02 D C B A in the shell side while the hot reactor
effluent passes through the tube side.
Hot mixture of liquid and gas from 23 E 02 D C B A is taken to the
furnace 23 F 01.
FURNACE AND REACTOR SECTION
Pre heated Kerosene/MTO/ATF/RTF and recycle gas mixture is brought
to the reaction temperature in the furnace 23 F 01. The furnace is installed
with a top mounted APH with FD fans 23FD01 A/B were replaced with
natural draft burners forced draft low NOx and low excess air burners.
The modification in furnace was done in the view of savings in FO


15
consumption. This Furnace is provided with two passes both in the
radiation and convection sections. Symmetrical arrangement of inlet,
outlet and coils of the furnace helps in equivalent distribution of the
stream in both the passes.
Nevertheless, two hand valves on the pass entrance can be used to
regulate the flow distribution by matching the outlet process temperatures
and skin point temperatures.
EFFLUENT COOLING SECTION
The effluent from the reactor is cooled and partially condensed in a series of
heat exchangers as follows:
In the tube side of 23 E 01, the recovered heat is utilised to reboil the
stripper column 23-C-01 bottom material.
In the tube side of 23 E 02 A B C D the recovered heat is utilised to
preheat the feed and hydrogen.
In the shell side of cooler 23 E 03 A B, the waterbeing the coolant.
Finally the effluent is sent to the separator drum 23 B 01.
SEPARATOR DRUM, MAKE UP AND RECYCLE GASES SECTION
The reactor effluent splits into 2 phases in the separator drum 23 B 01:
- The liquid phase is sent to the stripper column 23 C 01 through bottom
level control valve.
- Top vapour is partially recycled by compressor 23 K01 A/B, K101 and
rest is sent to lube oil Hydro finishing Unit/ Vaporizer through 23B01
pressure control valve.
The liquid level in the separator drum is controlled by a regulator 23 LC
05. In addition, it is provided with a high level alarm and compressor cut
off device, 23 LAHCO 04, to prevent any liquid flow to recycle
compressor. At the top of the separator, a wire mesh sieve is provided to
stop liquid entrainment along with gases.
The pressure in the high pressure section is controlled by a controller
which allows the excess vapour phase to hydro finishing unit.


16
The separator drum is connected to an ejector to create vacuum in the unit
during start-up& shut down. The recycle gas along with the makeup gas
is compressed by parallel reciprocating compressors.
The make-up hydrogen gas from CRU/DHDS comes to the suction of
recycle gas compressors through a knock out pot.
STRIPPING SECTION
The liquid from the separator drum is pre heated in the exchangers 23 E
04 A/B and fed into the stripper column 23 C 01. This stream passes
through the lube side and recovers heat from the treated product through
the shell side.
The column consists of:
- 17 ballast trays, type two pass below the feed point and
- 8 ballast trays, type single pass above the feed point.
A part of the stripper bottom is reboiled in the heat exchangers 23 E 01
on the shell side recovering heat from the reactor.
RECOMPRESSING SECTION
The gas from the reflux drum, 23 B 02 goes via 23 B 02A to first stage of
the three parallel reciprocating compressors. A high level alarm is
provided in 23 B 02A.
In case 23 K 02 A/B in line:
The first stage discharge gas upon cooling in the water cooler is mixed
with the gaseous stream ex LOB/U-11 PF column/U-16 PF column
before sending to the knock out drum 23 B 04.
Off gas stream of U-37(LOB) can be diverted directly to 15CO2
bypassing U-23 using the jump over at battery limit.
The condensed hydrocarbons from the drum are sent to stripper column
regulated by the high level controller 23 LC 14. This drum is provided
with the high level alarm 23 LAH 13. The vapour from the knock out
drum are compressed in the second stage of the compressors cooled in a
water cooler 23 E 08 sent to the knock out drum 23 B 05. The vapours


17
separated from the liquid hydrocarbon are sent to the fuel gas or amine
unit.
CHEMICAL INJECTION
CORROSION INHIBITOR
DOSING OF ADDITIVES IN ATF RUN.





























18
DHDS BLOCK
DHDS block comprises of following main units:-
1. DHDS
2. RFCCU
3. ARU
4. SRU
5. MSQU


DIESEL HYDRO DESULPHURISATION UNIT
Purpose:
To reduce the sulfur content of the sour diesel and to
produce sweet diesel with sulfur content of less than 0.25/0.05 % by wt.
Sulfur removal:
Feed stocks to the union fining .Unit contain simple
mercaptanes, sulfides anddisulfides are easily converted to H2S. Feed
stocks containing hetero atomic,aromatic molecules are preceded by
initial ring opening and then sulfur removalfollowed by saturation of the
resulting olefins.
Nitrogen removal:
De-nitrogenation is generally more difficult than
desulphurization. The de-nitrogenation of pyridine proceeds by aromatic
ring saturation hydrogynolysis andfinally de-nitrogenation.
Oxygen removal:
Organically combined oxygen is removed by hydrogenation
of the carbon hydroxyl bond forming water and the corresponding
hydrocarbon .Olefin saturation: Olefin saturation reaction proceeds vary
rapidly and have high heat of reaction.
Aromatic saturation:
Aromatic saturation reaction is the most difficult and exothermic.


19
Metal Removal:
Metals are retained on the catalyst surface by a combination
of adsorption and chemical reaction. Removal of metal normally occurs
from the top of the catalyst bed and the catalyst has a certain maximum
tolerance for retaining metals.
Metal contained in the crude oil are usually nickel and
vanadium. Iron is found concentrated at the top of the catalyst bed as iron
sulfide, which is corrosive. Na, Ca and Mg are present due to the contact
of the bed with salted water or additives.
Improper use of additives, to protect the fractionator
overhead systems from corrosion or to control foaming, accounts for the
presence of P and Si. Lead may also deposit on the hydro treating catalyst
bed from reprocessing leaded Gasoline through the crude unit. The total
metal retention capacity of the catalyst system can be increased by using
a guard reactor or guard bed of catalyst specially designed for de-
metallisation.
Halide removal:
Organic halides such as chlorides and bromides are
decomposed in the reactor.The inorganic ammonium halides sides, which
are produced when the reactoreffluent is cooled, are dissolved binjecting
water into the reactor effluent or removed with a stripper off gas.
Process Description:
The DHDS unit is based on the diesel union fining process of UOP and
iscomprised of four main section
The feed section
Reactor circuit section
Separator or compressor section
Fraction section
Feed Section
The feed stocks consisting of mainly straight run gas oils and lightcycle
oil from FCCU from Storage first passes through feed filters and
feedexchangers heated by stripper bottoms material before entering a


20
combinedfeed coalescer and surge drum. The feed surge drum provides
surge volume to even out the fluctuationsin the feed entering the unit
.This surge volume allows the feed to the unit tobe kept as constant as
possible which maximize the catalyst life length. Feedfrom the feed surge
drum enters the feed pumps where its pressure is raised to allow the feed
to enter the reactor circuit. Feed from the feed pump is combined with the
recycle gas flow .Combined feed passes through cold and hot combined
heat exchangers where it is heated by reactor effluent material .Then the
feed is sent to the charge heater where it enters the reactor circuit sector
section.
Reactor circuit section
Combined feed from the feed section is heated to reaction
temperature in the charge heater. Then the feed and recycle gas are
proceeded in reactor 1and 2 which contain catalyst chosen for its ability
to absorb metal in the field and to provide the proper level of
desulphurization required to meet a specified diesel product property.
The reactor 1 has two beds with one intermediate quench point.Quench is
required due to the heat of the reaction and the need to limit the
temperature rise to maintain the proper catalyst cycle length for the
chosen space velocity
The reactor 2 is a single bed reactor. To monitor the operation of the
reactors bed, thermocouples are providing at regular intervals. Reactor
effluent material is cooled in the hot combined feed exchanger .Water is
injected into this stream before it enter the separator condenser. After
cooling to the appropriate temperature, this is separated in the separator
into vapor and liquid hydrocarbons phases to decant the sour water phase.
The vapor from the separator is cooled in recycle gas cooler before
entering the scrubber KO drum.
The purpose of the recycle gas exchanger is to decrease the due point of
the recycle gas so as to greatly lessen the possibility of condensing
hydrocarbons material in the recycle gas scrubber, such HCs
condensation contributes to the foaming of the amine.




21
Process Flow Diagram:



REGENERATION FLUIDISED CATALYTIC CRACKING
UNIT
Introduction:
Indian Oil corporation limited (IOCL), Haldia Refinery has set up a
700,000 metric tons per annum capacity Fluid catalytic cracking
unit(FCCU) at Haldia,West Bengal.
The new plant mainly consist of reactors, regenerators, main
fractionators, product recovery section including amine treating
facilities Cracking reaction cracks down the long chain higher
molecular weight hydrocarbon into the lighter molecular weight
hydrocarbon .In course of cracking reaction, coke is also produced
which remains on the catalyst particles and rapidly reduces its
surface activity. In order to maintain the catalyst activity at a useful
level, it is necessary to regenerate the catalyst by burning off the


22
deposited coke.To achieve this , the catalyst continuously flows
from reactor to regenerator, where coke is burnt off in the presence
of oxygen.

Cracking Processes:
Cracking is a phenomenon by which large oil molecules are
decomposed into lower boiling molecules. At the same time certain
of these molecules, which are reactive, combine with one another
to give even larger molecules than those present in the original
stock.In modern refining industries there are three basic processes
for the conversion of heavy oil into useful products namely thermal
cracking, fluidised catalytic cracking and hydrocracking.

Process Description

Process Chemistry Theory:
Cracking process uses high temperature to convert heavy
hydrocarbons into more valuable lighter products. This can be done
either by thermal cracking or catalytic cracking. Catalytic cracking
process has almost superimposed thermal cracking because of
inherent advantage of low temperature and pressure. Catalytic
cracking produces higher octane gasoline, a more valuable cracked
gas and less of undesirable heavy residual products. Theory of
catalytic cracking is based on carbonium ion formation and
subsequent hydrogen transfer reaction.

Brief Process Description:
Fluidised cracking unit consists of the following sections:
1. Feed preheat section
2. Reactor/Regenerator section
3. Flue gas section
4. Catalyst Handling section
5. Main fractionators section


23
6. Product recovery section
7. Amine treating section
Feed Preheat Section-
Cold feed from FCCU feed tank and hot feed from process units
are combined and received feed surge drum, cold feed enters feed
surge drum on level control and hot feed enters surge drum on flow
control.
A water boot on the drum allows for manual draining of any water,
which may accumulate during start up upset conditions.The feed
drum pressure floats on the main fractionator by means of a
balanceline which ties into the fractionators below the LCO draw
chimney tray.

AMINE REGENERATION UNIT
Introduction:
Indian Oil Corporation Ltd. (IOCL) Haldia Refinery has Diesel
Hydro De Sulphurisation Unit (DHDS) for meeting the H
2
S
removal application for 2000 AD. To meet the requirement a new
Amine Regeneration Unit (ARU 26) is installed. The function of
the unit is to supply lean amine to and regenerate rich amine from
various users located in the DHDS unit. The ARU consists of 4
sections the rich amine section, the amine regeneration section, the
lean amine section and the amine storage section. The acid gas
from the ARU overhead is routed to the SRU and the lean amine to
the DHDS unit Rich amine from Catalytic DE waxing unit shall be
routed to ARU to meet this enhanced load minor revamp is done.
Design Basis:
Unit Capacity:-
Design Capacity- The design capacity of the ARU is 118526
kg/hr. Increased load due to CDWU is 20176 kg/hr.
Turn down Capacity- The turndown capacity of the ARU is
50%.
On Stream Factor- The on stream factor per year is 8000
hours.


24
PROCESS DESCRIPTION:
Battery Limit Conditions-






Feed Characteristics:-

Product Lean Amine to
DHDS
Acid Gas
Temperature
O
C 43.3 40
Pressure kg/cm
2
g 12.5 1.0
Feedstock Rich Amine
Ex DHDS
Temperature
O
C 50.4
Pressure Kg/cm
2
g 2.04
Rich Amine ex DHDS unit and CDW unit
(Kmol/hr)

DHDS Unit CDW Unit



H
2
O 4837.20 806.20
DEA 276.37 46.03
H
2
S 90.210 14.79
H
2
0.175 ----
CH
4
0.029 0.005
C
7
H
6
0.044 0.064
C
3
H
8
0.009 0.011
C
4
H
10
0015 0.025
C
4
<C> 0019 0.004


Total */ 5203.96 876.05


25
Brief Process Description:
For simplicity, only the chemistry involved in H2S removal is discussed.
Hydrogen Sulphide, H2S or HSH, is a weak acid and ionizes in water to
form Hydrogen ions and sulphide ions:
H
2
S + H
2
O H
3
O
+
+ HS
-
Since it is a fairly weak acid, only a fraction of the H2S will ionize.
Similar ionization will occur for the other acidic compounds present.
Di-EthanolAmine (DEA) is a secondary amine. The overall reaction
occurring in the DEA process can be represented by the following
equation:
(HOCH
2
CH
2
)
2
NH+H
2
S (HOCH
2
CH
2
)
2
NH
2
+
+HS
-
.
Detailed Process Description-
Rich Amine Section- the Rich Amine System receives the collected rich
amine from the amine absorbers, located in the Diesel Union fining Unit.
Sources include the Recycle Gas Scrubber, located in the reactor section
and the stripper Gas Amine Absorber and located in the fractionation
section of the Diesel Union fining Unit. Rich amine from the Recycle Gas
Scrubber and Stripper Gas Amine Absorber is combined outside battery
limit and sent directly to Rich Amine Flash Drum 26-V-01.
Amine Regeneration Section- The Rich Amine flash drum 26-V-01
separates any entrained liquid or gaseous hydrocarbon from the rich
amine. Liquid hydrocarbon is separated into a reservoir in 26-V-01 and
will be periodically pumped to a slop oil system by slop oil pump 26-P-
05 A/B. Hydrocarbon vapour separated in 26-V-01, which also contains
some H
2
S is scrubbed with a small lean amine slipstream in the stack
portion of the drum. The stacked portion consists of Carbon Raschig
Ring random packing to provide intimate contact between the flash gas
and the lean amine. The sweetened flash gas flows through back pressure
control valve PV-6203 to the acid gas relief header. The drum operates at
the pressure of 1.93 kg/cm
2
g.
Rich amine now flows from the bottom of 26-V-01 to Rich amine pump
26-P-01 A/B and then through the tube side of rich lean amine exchanger
28-E-02 A/B. In 26-E-02 A/B the rich amine is heated while the lean


26
amine from the bottom of amine stripper 26-C-01 is cooled. The heated
rich amine flows through the control valve LV-6202(used to control the
level in 26-V-01) and into 26-C-01. Stripper 26-C-01 strips nearly all of
the H
2
S from the rich amine, thus regenerated it to lean amine. The
stripper contains 23 valve trays with which 20 trays in the stripping
section and 3 trays in the wash section. Stripping steam is generated in
the Amine Stripper Reboilers 26-E-03 A/B by vaporising a portion of the
water in the column bottoms (lean amine). A small amount of live
stripping stream is also injected into one the re-boiler return lines (14-P-
26-6511) in order to water balance the entire amine system. The stripping
stream flows up through the column, helping to evolve H
2
S from the rich
amine and heating the solvent to boiling point. Reboilers 26-E-03 A/B
use de superheated MP stream as the heating medium. The re boiler
heating rate is controlled by low selector FY-6502B of steam flow
controller FIC-6502 and pressure controller PIC-6507. The absolute
maximum temperature of the de superheated steam is 160OC in order to
prevent amine degradation Condensate from the re-boilers condensate
return system is used as the water source to de-superheat the reboilers
heating steam. Condensate from 26-E-03 A/B flows to condensate Drum
26-V-04.Whatever is not used for de superheating water or as makeup
water to the Diesel Union fining Unit is pumped to the condensate header
with condensate pump 26-P-04 A/B under level control(LIC-6601).
Acid gas from the top of 26-C-01, containsH
2
S, some light hydrocarbons
and water vapours is cooled to drop the temperature (Condensing most of
the water) to minimise the water loss in the overhead in this overhead
steam. The gas is first cooled in Amine Stripper Condenser 26-AC-06 and
then further cooled in Amine Stripper Trim Cooler 26-E-04. The two
phase stream flows to Amine stripper Receiver 26-V-02 where the water
is separated from the remaining acid gas steam. The water from 26-V-02
is pumped via Amine stripper Reflux pump 26-P-03 A/B as reflux back to
the top tray of 26-C-01. The acid gas from the top of 26-V-02 is normally
to the SRU. At shut down of the SRU or if the SRU is not in operation
acid gas is sent to the acid gas relief header through pressure control
valve PV-6505B. Theacid gas pressure is controlled with pressure control
valve PV-6505 via a split ring configuration at a pressure of 1.77
kg/cm
2
g. The bottom of 26-C-01 is used as a surge volume for lean amine
to a temperature (43.3
O
C), which can be used by the amine scrubber and


27
absorbs in the Diesel Union fining Unit. The outlet temperature of 26-E-
01 is kept from getting too low by temperature controller TIC-6402. This
acts on the lean amine by pass around the trim cooler. The lean amine
then flows to the filtration system, which filters approx. 10% slipstream
of lean amine through a sense of three filters.
Lean Amine Section- Some lean Amine is used inside the amine unit
battery limits as a wash for the Rich Amine flash Drum stack them is also
a start-up line, which allows lean amine to be re-circulated through the
regeneration section only, flowing back to 26-V-01. The remainder of the
lean amine then leaves the Amine unit and serves the absorbers in the
DHDS Unit. These absorbers include: the Recycle Gas Scrubber located
in the Reactor section and the Stripper Gas Amine Absorber located in
the Reactor Section and the Stripper Gas Amine Absorber located in the
Fractionating Section. The Reactor section scrubber operates at a
significantly higher pressure than the other absorber, so a booster pump is
required to supply the lean amine at a sufficient pressure for the Recycle
Gas Scrubber. This pump is located in the Diesel union fining Unit.

Amine Storage Section- High purity amine (99 wt.% DEA) is to
supplied to ARU 26 in bulk quantity (for s/u) and in drums. The Amine
Melt Tank 26-V-07 is used to empty drums and to melt the amine. The
melted DEA or the DEA in bulk quantity is transferred to Amine Storage
Tank 26-T-01 via Amine Transfer Pump 26-P-07 A/B and is diluted to a
25 wt.% solution in water with cold condensate from the refinery as water
source. This pump can also be used to mix the contents of 26-T-01
through a recirculation line with a jet mixer located inside the tank. The
25 wt% DEA Solution in water is periodically pumped (via 26-P-07 A/B)
to the regeneration section to replenish the amine supply. The amine can
be pumped to the suction of Lean Amine Pump 26-P-02 A/B and the
suction of Rich Amine Pump 26-P-01 A/B. Addition of amine will result
in an increase in the level of Amine Stripper 26-C-01. Amine storage
Tank 26-T-01 is also used to old the entire inventory of the Regeneration
Section, when it needs to be shutdown. The pump out line is on the lean
amine stream just downstream of the Lean Amine Coolers. The cooled
lean amine is transferred over to 26-T-01 via 26-P-02 A/B and can be
replaced using 26-P-07 A/B when the train is ready to be re-inventoried.



28
SULPHUR REGENERATION UNIT
Introduction:
The sulphur recovery unit-28/83 of haldia refinery consists of a
single train to recover sulphur from acid gases from amine
regeneration unit(UNIT-26) and sour water stripper off gases ex
refinery sour water stripper(UNIT-29).This unit based on claus
recovery concept.It is consisting of one thermal reactor and four
catalytic converters for recovery of sulphur from above
streams.The equipments in the unit shall be divided into three main
sections, namely the thermal reactor section ,claus section and tail
gas incineration section.The sulphur recovery section shall include
knock out drums for various inlet streams,a main burner,a main
combustion chamber,a waste heat boiler, sulphur
condenser,catalytic converter-1,catalytic converter-2,catalytic
converter-3,and super claus catalytic converter,a sulphur pit to
storage liquid sulphur,sulphur pumps,pit ejector etc.The tail gas
incineration section includes thermal incinerator burner and vent
stack for disposing of the flue gas from incinerator containing
sulphur dioxide.Flue gases produced by incinerating the tail gases
shall be vented through stack to disperse the sulphur dioxide.Stack
is designed for two trains each of 60TPD sulphur capacity.A
minimum stack height of 50m is provided.Sulphur recovered in the
process is stored in the pit and is pumped to a yard where sulphur
lumps are produced by quenching the ,molten sulphur using service
water.
Sulphur Recovery Rate:
The unit is capable of a sulphur recovery rate of 99 wt%
based on operation of the unit at a capacity and acid gas
composition corresponding to one of the cases as defined.
Unit Capacity:
Design Capacity-
The unit consists of one SRU with a sulphur production capacity of 60
metric tons/day.


29
Turndown Capacity-
The turndown of the unit is 30% on the normal feed gas rate.
On-stream Factor per year is 8000 years.
Design Feed Chsrscterstics
The feed stock of the SRU is a mixture of the acid gas ex ARU
and the Acid gas ex SWS,the unit should be capable of
converting 99% wt of the hydrogen sulphide contained in the feed
streams to sulphur in all the following cases.

Case-1, design case


Design Product Characteristics

The product sulphur will meet the following specification after degassing
State : liquid sulphur
Colour: bright yellow(as solid state)
Purity: min 99.9wt% on dry basis
acid gas ex-ARU
(kg/h)
acid gas ex-SWS
(kg/h)
total feed
(kg/h)
water
hydrogen
sulphide
ammonia
hydrogen
methane
ethane
prpopane
butane
pentane
carbondioxide

Total


64.10
2658.80
-
0.30
3.38
1.36
0.32
1.27
1.71
-

2731.24
34.10
58.82
16.49
-
-
-
-
-
-
-

109.41
98.20
2717.62
16.49
0.30
3.38
1.36
0.32
1.27
1.71
-

2840.65



30
Hydrogen sulphide content: 10ppm weight max.
Process Summary:
The sulphur recovery process applied in design,which is known as the
SUPERCLAUS process, is based upon the partial combustion of
hydrogen sulphide (H
2
S) with a ratio controlled flow of air, which is
maintained automatically in a correct quantity to accomplish the complete
oxidation of all hydrocarbons of 0.5-0.7vol% at the selective oxidation
reactor(SUPERCLAUS reactor).
In the conventional claus process the air to acid gas ratio is mainted to
produce an H
2
S/SO
2 ratio
of exactly 2/1 in the burner effluent gases.This is
known to be the optimum ratio of H
2
S/SO
2
for the claus reaction.In this
process the air to acid gas ratio is adjusted to achieve an H
2
S/SO
2
ratio
of greater than 2/1 in the burner effluent.
In the other words , the front end combustion is operated on H
2
S/SO
2
ratio control H
2
S-SO
2
analyzer AT-0801 is provided on effluent gas
stream from the 4
th
sulphur condenser to measure the H
2
S concentration
and to control the trim air to the main burner to achieve the desired H
2
S
concentration at this point in the process.From an overview standpoint,
the control philosophy may be summarized as :
If the H
2
S concentration entering the SUPERCLAUS stage is too
high , more air is added to the main burner to create more SO
2
.
If the H
2
S concentration entering the superclaus stage is too low,
less air is added to the main burner.
Process Description:
H
2
S + 3/2 O
2
-> SO
2
+H
2
O +heat
The major part of residual H
2
S combines with SO
2
to form sulphur,
according to the equilibrium reaction
2H
2
S +SO
2
< -> 3/2 S
2
+2H
2
O - heat
By this reaction , known as the claus reaction,sulphur is formed in
vapourphase in main burner and combustion chamber .The primary


31
function of the waste heat boiler is to remove themajor portion of heat
generated in the main burner.
The secondary function of the waste heat boiler is to utilize the above
mentioned heat to produce MHP steam.
The process gas from the waste heat boiler is passed into the 1
st
sulphur
condenser,where the formed sulphur is removed from the gas.
The process gas leaving the sulphur condenser still contains a
considerable concentration H
2
S and SO
2
, there for the essential function
of the following equipment is to convert these components to sulphur.
In the 1
st
,2
nd
and 3
rd
reactor stages the H
2
S and SO
2
react again to form
sulphur, but this time at low temperatures.
In the superclaus stage the remaining H
2
S is selectively oxidized to
sulphur.For this reason it is essential that the combustion in main burner
is such that down stream the 3
rd
reactor stage the amount of H
2
S in the
range of 0.5-0.7 vol% and that the SO
2
concentration is as low as
possible.
Before entering the 1
st
reactor, the process gas flow is heated by indirect
steam reheat to obtain the optimum temperature for high conversion of
H
2
S and SO
2
to elemental sulphur and simultaneously a high conversion
of COS and CS
2
to H
2
S and CO
2
.
In the 1
st
reactor the H
2
S and SO
2
react again until equilibrium is reached.
2H
2
S+ SO
2
<->3/8 S
8
+2H
2
O+heat
The effluent gas from the 1
st
reactor passes to the 2
nd
sulphur condenser.
The process gas flow is routed to the 2
nd
sulphur reheater , then passed to
the 2
nd
reactorwhere equilibrium is established.The sulphur is condensed
in the 3
rd
sulphur condenser.
The process gas from the 3
rd
sulphur condenser is routed to the 3
rd
steam
reheater ,then passed to the 3
rd
reactor where equilibrium is
established.The sulphur is condensed in 4
th
sulphur condenser.



32
SUPERCLAUS SECTION
The process gas from the 4
th
sulphur condenser is routed to the 4
th
steam
reheater, then passed to the reactor.Before it enters the reactor a
controlled amount of air is added.Proper mixing isobtained in in a static
mixer .In the reactor H
2
S reacts with oxygen to sulphur according to the
reaction.The sulphur is condensed in 5
th
sulphur condenser.The sulphur
coalesce is installed downstream of the last sulphur condenserto separate
entrained sulphur mist.The sulphur condensed and separated in the
condensers and coalesce is drained via the sulphur locks and sulphur
coller in the sulphur pit.
SULPHUR STRIPPING PROCESS
The produced sulphur contains H
2
S,partly dissolved and partly present in
form of polysulphides.The function of this process is to enchance the
decomposition of polysulphides and to strip the H
2
S from sulphur
simultaneously the greater part of H
2
S is oxidized to sulphur.This is done
by bubbling air through the sulphur. The air decreases the partial pressure
of the H
2
S and causes agitation and circulation of sulphur.In this way the
H
2
S content is reduced from approximately 350 to less than 10 ppm wt.
PROCESS FLOW DIAGRAM:



33
MOTOR SPIRIT QUALITY UPGRADATION UNIT(MSQU)

INTRODUCTION:

Process Chemistry Overview:
Thermodynamics and kinetics- For any chemical reaction, the
thermodynamics dictates the possibility of its occurrence and the amount
of products and unconverted reactants. In fact, some reactions are 100%
completed i.e. all the reactants are converted into products. Other are in
equilibrium i.e. part of the reactants are only converted. The amount of
products and reactants at equilibrium depends upon the operating
conditions and is dictated by the thermodynamics. Note that the
thermodynamics does not mention the time required to reach the
equilibrium or the full completion of a reaction.
Kinetics dictates the rate of a chemical reaction (i.e. the amount of feed
that disappear in say, one second). Kinetics (rate of reaction) is dependent
upon operating conditions but can also be widely modified through the
use of properly selected catalyst.
In other words thermodynamics dictates the ultimate equilibrium
composition assuming the time is infinite. Kinetics enables the prediction
of the composition after a finite time. Since time is always limited, when
reactions are concurrent, kinetics is generally predominant.
A catalyst generally consist of a support (earth oxide, alumina, silica,
magnesia) on which finely divided metal(s) is/are deposited. The metal is
always responsible for the catalytic action. Very often the support has
also a catalyst action related to its chemical nature.

Catalyst activity, selectivity, stability-
The main characteristics of a catalyst other than its physical and
mechanical properties are:
The activity which is the catalyst ability to increase the rate of the
reactions involved. It is measured by the temperature at which the
catalyst ability I increased the rate of the reactions involved. It is
measured by the temperature at which the catalyst must be


34
operated to produce a product on specification, for a given feed, all
other operating conditions being equal.
The selectivity expresses the catalyst ability to favour desirable
reaction rather than others.
The stability characteristics the change with time of the catalyst
performance (i.e. activity, selectivity) when operating conditions
and feed are stable. It is chiefly the polymers or coke deposit where
affects stability, because it decreases the metal contact area. Traces
of metal in the feed also adversely affect stability.

Chemical Reaction- The purpose of the Naphtha Hydro treatment unit is
to protect the isomerisation catalyst by eliminating or reducing to an
acceptable level the impurities present in the naphtha stream. Impurities
such as sulphur, nitrogen, water, halogens, di-olefins, olefins, mercury,
arsenic and other metals are detrimental to catalytic activity. The
treatment process is achieved by passing the naphtha over a bimetallic
catalytic bed in an adiabatic reactor in the presence of hydrogen.
There are principally two fundamental reactions occurring:
-Hydro refining
-Hydrogenation
Hydro refining:
This refers to the replacement of the contaminant molecule with
hydrogen. Major hydro refining reactions include desulphurisation,
denitrification and de- oxygenation. These are explained in sections
that follow.
a) Desulphurisation:
Sulphides, disulphides and mercaptans react readily to
produce the corresponding saturated or aromatic compound
releasing H
2
S.
RSR + 2H
2
RH+RH+H
2
S
RSSR+3H
2
RH+ RH+2H
2
S
RSH+ H
2
RH+ H
2
S
Sulphur combined in an aromatic structure like thiophene is
more difficult to react.
b) Denitrification:
This reaction occurs at a slower rate than desulphurisation.
Here nitrogen is released to form ammonia.


35
R-NH
2
+ H
2
R-H + NH
3

c) De- Oxygenation
Similar to denitrification, de- oxygenation reactions are
much more difficult than desulphurisation. Oxygenated
contaminants are not significant problem in virgin naphtha
but more prevalent in cracked and synthetic naphthas. In the
de- oxygenation reactions, the CO bond is broken and the
corresponding saturated aliphatic or aromatic is formed
together with water.


+ H
2
+ H
2
O

Phenol OH Benzene

Hydrogenation- Hydrogenation or olefin saturation is the addition of
hydrogen to an unsaturated hydrocarbon to produce a saturated product.
Olefinic hydrocarbons are not normally present in straight run naphthas
but can be found in high concentrations in cracked naphthas. The olefin
saturation reaction is highly exothermic and proceeds relatively easily
and quickly (in top section of the catalyst bed).

CH
3
-CH
2
-CH=CH-CH CH
3
-CH
2
-CH
2
-CH
2
-CH
3

CH
3
-CH
2
-CH
2
-CH
2
-CH=CH
2
CH
3
-CH
2
-CH
2
-CH
2
-CH
2
-CH
2
-CH
3
Olefins at temperature involved in reforming process (about 500
o
C) result
in coke deposits on the reforming catalyst and hence must be
hydrogenated to avoid coke deposition on catalyst. Olefins hydrogenation
reactions are exothermic. Heat of reaction is around 30 Kcal/mol.
Minimal hydrogenation of aromatics occurs, estimated at less than one
per cent. This is a consequence of high selectivity of the AXENS
bimetallic catalyst.



36
Catalyst characteristics-
There are two catalysts used in the Hydro treatment unit: HR-945(1
st
bed
of the reactor) for Olefins hydrogenation and the HR-448 (2nd bed of the
reactor) for the desulphurisation and the denitrification.
The main features of all the hydro treating catalysts are:
High purity alumina support having a strong resistance to attrition.
High stability and selectivity towards the desirable hydro treating
reactions.
Ease of regenerability.
The association of the above qualities gives the following advantages:
Efficient hydro treating.
Minimal yield loss.
Long catalyst life.
Catalyst mechanism: Reaction mechanisms in catalyst naphtha hydro
treating are known only for a few reactants and results are not easily
generalised. As desulphurisation is the predominant reaction taking place,
using thiophene as a model reactant, studies have shown that the first
reaction of thiophene is the C-S bond cleavage to form 1,3 butadiene,
rather than hydrogenation of the C=C bond.
e.g.
+ 2H
2
CH=CH-CH=CH
2
+ H
2
S

s
Thiophene Butadiene
The subsequent reaction is then:
CH=CH-CH=CH
2
+2H
2
CH
3
-CH
2
-CH
2
-CH
3
Process flow description:
The following process description includes following sections:
-Naphtha splitter
-NHDT (Naphtha Hydro treatment)
-Reformer splitter


37

Naphtha Splitter
The straight run naphtha enters the unit at the battery limit conditions (4.0
kg/cm
2
g and 40
O
C) and is directed to SR naphtha surge drum 85-B-01 is
maintained under a pressure of 1.5 kg/cm
2
g by blanketing with fuel gas
using split range pressure controller. The fuel gas blanketing is provided
in the surge drum 85-B-01 to maintain constant pressure 1.5 kg/cm
2
g in
the surge drum is order to avoid ingress of air and formation of explosive
mixture. The fuel is admitted to PIC- 0103 when pressures in the surge
drum falls below the set point. When the pressure in the surge drum
exceeds the set point PIC-0130 releases the pressure to flare header.
The naphtha is pumped under flow control FIC-0105 by naphtha splitter
feed pump 85-P-01 A/B. One pump is working and other is standby. The
stand by pump shall be started manually. The naphtha splitter feed pump
85-P-01 A/B is provided with minimum flow by pass line through flow
controller. When the process flow becomes less than pump minimum
flow requirement on minimum flow by pass line will open to maintain
pump minimum flow. The pump minimum flow by pass line is connected
to surge drum 85-B-01 SR naphtha feed inlet line. The naphtha splitter
feed is heated by hot naphtha splitter bottoms from 85-P-04 A/B in
naphtha splitter feed/effluent exchanger 85-E-01 A/B and enters the
naphtha splitter column 85-C-01 on tray #26 at 94
O
C.
The liquid hydrocarbon is pumped by the naphtha splitter reflux pump
and split into 3 parts:
1> One part is sent to the column as reflux under flow control FIC-0101
cascaded with temperature control on tray #37 of splitter column.
2> A part is sent as light naphtha to NHDT unit under flow control FIC-
0203(slave) that is cascaded with the level controllerLIC-
0201(Master) in the SR Naphtha surge drum.
3> Rest is mixed under flow control that is cascaded with level controller
in the naphtha splitter reflux drum with heart cut and sent to the
storage as excess naphtha.
A side cut (heart cut) is withdrawn on tray #31 under level control. It is
pumped by 85-P-02 A/B (1 working+1 standby) under flow control,
mixed with a part of light naphtha and cooled and sent to storage as
Excess naphtha. 85-P-03 A/B is provided with minimum flow bypass
line.


38
The NHDT unit is designed to process light naphtha combined with FCC
gasoline heart cut. However, a slip stream of naphtha heart cut may be
injected in the light naphtha as NHDT feed. The quantity of naphtha heart
cut shall be limited to 30% of the total naphtha fed to the NHDT unit.
Heavy naphtha from the naphtha splitter bottom is pumped by 85-P-04
A/B (1 working + 1 standby), cooled by 85-E-01 A/B and 85-E- 04. Then
it is sent under flow control with level reset to catalytic reforming unit via
storage.
Further, the whole process is divided into different sections namely:
Reaction Section
Stripper section
Reformate splitter
Catalyst in- situ regeneration operation.
















39
ONCE THROUGH HYDROCRACKER UNIT
OHCU comprises of three units
1. Hydro cracker
2. Hydrogen Generation unit
3. Nitrogen generation unit

Hydrocracker
Feed: Straight run gas oil, Vacuum gas oils, Cycle oils, Coker Gas oils,
thermally cracked stocks, Solvent de asphalted residual oils, straight run
naphtha, cracked naphtha.
Product: Liquefied petroleum gas (LPG), Motor gasoline, Reformer
feeds, Aviation turbine fuel, Diesel fuels, heating oils, Solvent and
thinners, Lube oil, FCC feed
Hydro cracking processes involved two types of catalyst:
1 Hydro pre treatment catalyst
2 Hydro cracking catalysts
1. Hydro treating (Pre treat) Catalyst
The main objective of pretreat catalyst is to remove organic nitrogen from
the hydro cracker feed allowing
(i) Better performance of second stage hydro cracking catalyst, and
(ii) The initiation of the sequence of hydro cracking reactions by
saturation of aromatic compounds
Pre treat catalyst must have adequate activity to achieve above objectives
within the operating limits of the hydrogen partial pressure, temperature
and LHSV.
2. Hydro cracking Catalyst: Hydro cracking catalyst is a bi-functional
catalyst and has a cracking function and hydrogenation dehydrogenation
function. The former is provided by an acidic support whereas the latter is
imparted by metals. Acid sites (Crystalline zeolite, amorphous silica
alumina, mixture of crystalline zeolite and amorphous oxides) provide


40
cracking activity. Metals [Noble metal (Pd, Pt) or non- noble metal
sulphides (Mo, Wo or Co, Ni)] provide hydrogenation dehydrogenation
activity. These metals catalyze the hydrogenation of feed stocks making
them more reactive for cracking and hetero-atom removal as well
reducing the coke rate
Zeolite based hydro cracking catalysts have following advantages of
greater acidity resulting in greater cracking activity; better
thermal/hydrothermal stability; better naphtha selectivity; better
resistance to nitrogen and sulphur compounds; low coke forming
tendency, and easy regenerability.
The unit consists of the following sections:
1. Furnace
2. First stage Reactor section
3. Second stage Reactor section
4. High pressure separator
5. Fractionation Section
6. Light Ends Recovery section
Effect of Operating Parameters
Various operating parameters affecting hydro cracking are
Reaction temperature, Hydrogen partial pressure, Hourly feed
velocity of the feed, Hydrogen recycle ratio
Temperature increase in temperature accelerates cracking reaction on
acid sites and displaces the equilibrium of hydrogenation reactions
towards dehydrogenation. Too high temperature limits the hydro
cracking of aromatic structure .The pressure influences significantly
the equilibrium of dehydrogenation-hydrogenation reactions that takes
place on the metallic sites. The increase in pressure for a given molar
ratio H
2
/feed corresponds to increase in the partial pressure of
hydrogen, will produce an increase the conversion of the aromatic
structures to saturated products which will improve the quality of jet
fuel, diesel fuel and oil with very high viscosity index.



41
Effect of Feedstock:
A higher content of aromatic hydrocarbons requires higher
pressure and higher hydrogen/feed ratio, the lowest possible
temperature and a higher hydrogen consumption of hydrogen and the
severity of the process
Effects of Feed Impurities:
Hydrogen sulphide, nitrogen compounds and aromatic molecules
present in the feed affect the hydro cracking reactions. Increase in
nitrogen result in lower conversion. Ammonia inhibits the hydro cracking
catalyst activity, requiring higher operating temperatures. Polymeric
compounds have substantial inhibiting and poisoning effects. Poly
nuclear aromatics present in small amount in the residue deactivate the
catalyst.




42

Process Flow Diagram:



43
Hydrogen generation Unit

Purpose-
To cater the refinery hydrogen demand in order to produce low
sulphur& high quality products from hydro treater and hydro cracking
Introduction: - Hydrogen generation unit was commissioned with a
capacity 10,000 metric tonnes per annum of 99.99% pure hydrogen that
subsequently increased to 150000 MTPY with a revamp in may 2003.
Feed is mixture of naphtha & FCC gasoline in ratio of 80:20 by wt .feed
impurities are unsaturated hydrocarbon sulphur& chlorine.
Chemical reaction
Basic reaction
RSH + H
2
RH + H
2
S
RCl + H
2
RH+ HCl
R=R + H
2
R-R

Process description:-it consist of following main process step
1. Pre-desulphurization :- Unsaturated component as well as high
amount of organic sulphur is removed from feed by catalytic
conversion which is separated from naphtha by distillation
R
1
SS
2
+ 3H
2
R
1
H + R
2
H + 2H
2
S

COS + H
2
CO + H
2
S
2. Final desulphurization: - In this further catalytic hydrogenation of
the residual organic sulphur followed by adsorption of the
hydrogen sulphide on selective adsorbent bed. ZnO bed and
CoMox catalyst are used for the removal of the sulphur and
chlorine compound
RCl + H
2
RH + HCl




44
3. Pre- reforming:- In this the feed is reacted in presence of steam to
give a mixture of methane, carbon dioxide and hydrogen over a
nickel bed catalyst
C
n
H
m
+ n H
2
O CO +

(m+n) H
2

CO
2
+ 4H
2
CH
4
+ 2H
2
O
CO + H
2
O CO
2
+ H
2

4. Reformer :- In order to achieve high yield of hydrogen from the feed
stock after pre reforming methane is converted in reformer which
operate at high temperature
5. Shift conversion: - the process gas leaving the reforming section
contains carbon monoxide which is converted into CO
2
and hydrogen.
The reactor is operated at lowest possible temperature in order to
recover the heat and the hydrogen generation from the feed stock.
there are two temperature at which reactor are operating high
temperature shift and low temperature shift
CO + H
2
O CO
2
+ H
2
6. Pressure swing adsorption :- PSA technology is used to remove
impurities form reformer gas this is achieved by molecular sieve
which adsorb the contaminant and allow the hydrogen to pass
Simplified flow sheet










PREDESULPHURIZATION
VAPORIZATION
DESULPHURIZATION
PREREFORMER &
REFORMER
CONVECTION SECTION
HIGH TEMP. &
LOW TEMP.
SHIFT CONVERSION
DUAL STEAM
SYSTEM
HEAT RECOVERY
AND COOLING
PRESSURE
SWING
ADSORPTION


45
PROCESS FLOW DIAGRAM:


Nitrogen Generation Unit

Properties of Nitrogen:
Nitrogen is a diatomic gas which constitutes 78%
of the earth atmosphere. Its atomic weight is 14
Physical Properties: Colourless, Odourless, and Tasteless
Chemical Properties: 1.Density (at 0 C and 1 atm): 1.251 g/l
2. Dew Point :: -172 C


46
3. Melting Point: -210
0
C
4. Boiling Point : -195.8
0
C
Properties of Oxygen:
Oxygen is a diatomic gas which constitutes about 21% of
the earths atmosphere. It is most commonly found in its diatomic form
which is molecular oxygen (O
2
) and the triplet state known as Ozone (O
3
)
which is a highly active compound. Its atomic wt is 16.
Physical Properties: Colourless , Odourless, Tasteless
Chemical Properties:
1. Density (at 0 C and 1 atm) :: 1.432 g/l
2. Dew Point :: -165 C
3. Melting Point :: -218.4
0
C
4. Boiling Point :: -183.0
0
C

Raw materials
1- Air
Process description:

It consists of following section-Air Compression Section, Refrigeration
Section, Pre-Purification Section, Cold Box, and Storage Tanks.
Air compression section:-The Air compressors receive air through Air
Suction Filter and then pressurized dust and oil free air is discharged to
the Refrigeration Section. This Section consists of a 3-stage Compressors
Refrigeration Section:-Air enters the Refrigeration section DX Chiller
where it is cooled down to a temperature of about 8 to 12 deg
C.Refrigerant Used-1,1,1,2 tetra fluoro ethane(R134A).Vaporized R134A
returns to the REFRIGERATION COMPRESSOR and is discharged to
the CONDENSORS where it is cooled down by cooling water. The


47
liquid R134A is then routed to vapouriser96-E-14 after exchanging heat
with gaseous R134A and partial vaporisation through where it again cools
the air by gaining latent heat of vaporisation from the air.
Pre-Purification Section:-AIR has been cooled to 8-12
o
C at 8.7 kg/cm2,
thus a part of Saturated Water is condensed. To separate this moisture air
is sent to the Moisture Separator. Then the air is sent to one of the two
ADSORBERS . Here moisture traces and CO2 are removed through
Activated alumina and Molecular sieve beds respectively. These
Adsorbers adsorb impurities at a temperature of about 10
o
C and are
regenerated at a temperature of around 130 to 180
o
C. Thus they are
Temperature Swing Adsorbers .The heating for the regeneration is done
using an electric REGENERATION HEATER .After having passed
through the adsorbers the AIR is the directed to the COLD BOX through
FILTERS
Cold box section:-The Cold Box process can be divided into 3 parts:
Cooling down and liquefaction of air-: Air enters exchanger and is cooled
in counter current flow to outgoing pure N
2
, waste air coming from
column. The air flows out at partly liquid state and enters the lower part
of column.
Fractionating the air by distillation-: The air coming from exchanger
enters the bottom of column below the bed of trays at -165.8 deg C. The
vaporizer ensures the cooling down by its Rich Liquid bath and performs
condensation of the rising vapour. N2 which is in gaseous state is
received from the column top and O2 rich liquid is received from the
column bottom. This liquid is further used for the exchange of Cold
energy with incoming dry air.
Productions of the Column and Vaporizer:-From the top of the Column
the pure gaseous Nitrogen is available at about 10
o
C after having
exchanged heat in counter flow to treated air in exchanger. At the top of
the vaporizer 96-E-03 the Waste Air flows out at about 5.58 kg/sq. cm, -
171.23 deg C. This Waste Air is utilized expansion turbine, which
provides the necessary refrigeration for the plant by expanding the waste
air. At the outlet of the exchanger, a part of this Waste Air at about 13
o
C
and 1.2 kg/sq cm is utilized to regenerate the adsorbent beds of
Absorbers. From the liquid receiver at the upper part of the Column a part


48
of the pure Liquid Nitrogen can be drawn off as product. If purity of
Nitrogen is more than 3 ppm (vol.) oxygen, the gaseous Nitrogen
product is vented off.
Nitrogen Storage: A small portion of the reflux to Column C-01 is sent to
Tank T-01 A/B as liquid N
2
storage. In case of Plant Shutdown, and
header pressure down, LN (Liquid N
2
) is passed to vaporizers (96-E-
04A/B) which vaporizes LN to Gaseous state and supply to header. These
tanks are vacuum insulated so as to prevent the LN from vaporizing
inside the tanks.
Process Flow Diagram:








49


LUBE OIL BLOCK
Lube Oil Block comprises of the following units:
Vacuum Distillation Unit-I (U-31)
Propane De-Asphalting Unit (U-32)
Furfural Extraction Unit (U-33)
Solvent Dewaxing Unit (U-34)
Lube Hydrofinishing Unit (U-35)
Bitumen Blowing Unit (U-36) [now scrapped, as it is made a part
of PDA, U-36 R/D manifold]
Vis-breaking Unit (U-37)
NMP Extraction Unit (U-38)
Wax Hydrofinishing Unit (U-39)
Catalytic IsoDewaxing Unit (U-84)
The typical lube oil base stock processing circuit is shown below
for Haldia Refinery.
Lube Processing circuit in Haldia Refinery
A
t
m
o
s
p
h
e
r
i
c

d
i
s
t
i
l
l
a
t
i
o
n
V
a
c
u
u
m

d
i
s
t
i
l
l
a
t
i
o
n
S
o
l
v
e
n
t

E
x
t
r
a
c
t
i
o
n
S
o
l
v
e
n
t

D
e
-
w
a
x
i
n
g

o
r

C
a
t
a
l
y
t
i
c

D
e
-
w
a
x
i
n
g
H
y
d
r
o
f
i
n
i
s
h
i
n
g
Propane De-Asphalting
Gas
Naphtha
Kero
Diesel
RCO
VR DAO
Vacuum
Distillates
Waxy
Raffinates
De-waxed
oils
Lube
Base Oils
150N
500N
HN
VGO
KV,
Flash Point
VI, CCR Pour Point
Colour &
Stability
150BS
Crude
Oil



50

I mportant 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 I ndex (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 highest application temperature at which the oil
would work without getting deteriorated. [also this is an indicator
of vaporization loss]
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. Colour
Lube Oil Base Stock should be water-like in appearance, the colour
that is seen in most of the marketed lube oils are due to the
additives that are added in LOBS. This colour 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 unsaturated.


51
LOBS
(as per API)
VI SULPHER
%
SATURATES
%
GROUP I 80-120 >0.03 <90
GROUP II 80-120 <0.03 >90
GROUP III >120 <0.03 >90

Vacuum Distillation Unit
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
Capacity
250m3/hr, with Arab Mix /Upper Zakum RCO
Distillation
Parameters

Pressure 70 mmHg Absolute
Temperature 360-400 C
Licensor/
Technology
IPIP (Romania)

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


52
(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


53
Propane de Asphalting unit

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 cant 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
Capacity
800000 MT/Yr
Methodology
DAO is recovered by means of Extraction process with liquid
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
Feed Ratio
6 to 12
Licensor/
Technology
M.W. Kellog Technology Co. USA

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.



54
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.







55



M
/
U

P
u
m
p
s

Heater

E
121
A/B
H
P
A
s
3
2

D
A
O
D
A
O

M
i
x

P
u
m
p




32
C 06

3



Pro
pan
e
Bull
ets


3
2

C
W
D
r
To
Unit
M/U
Pum
ps



Steam
Steam



Air
fin
Cool
er
E
114
A/B/
C/D
E 119


56








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
Methodology
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
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
Ratio
1.2 to 2


57
Licensor/
Technology
IPIP (Romania)

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
vapours 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.



58









Solvent De Waxing unit
Purpose:-
To separate the wax from the Raffinates obtained from
Aromatic Extraction Units (FEU & NMPEU) to lower the pour point of
the products.
Feed Raffinates of (SO, LO, IO, HO) and DAO
Products


De-waxed oils of SO, LO, IO, HO and DAO
Slack wax of SO, LO, IO, HO and DAO
Unit Capacity 290000 MT/ Annum
Methodology

Extraction and crystallization to achieve de-waxing with the
addition of SDA (for BN feed only) followed by filtration &
Solvent Recovery

Solvent: MEK & Toluene in equal proportions. Toluene is oil
solvent & MEK is anti wax solvent.

Crystallization is done by chilling using Ammonia as a
refrigerant. Vapor ammonia is again compressed and
condensed for recirculation

Licensor/
Technology
IPIP (Romania)


59

Process description:-
The feed after dilution with the solvent is chilled in
a series of Double pipe exchangers (exchanges heat with filtrate)
followed by Ammonia chillers. The chilled blend is then filtered in
several Rotary Drum Filters where in the wax crystals get separated from
the oil phase. The two phase (Lube Mix and Wax Mix phase created by
filtration is routed to their respective solvent recovery (by distillation)
circuits. Recovered solvent is re-circulated into the system. De-waxed Oil
and slack wax are routed to their respective storage tanks.
Advantages:-
The process helps to separate the wax components from
the raffinates obtained from extraction units. The slack wax obtained as
by product during BN feed (DAO) is a suitable feedstock for producing a
very high value product called Micro Crystalline Wax (MCW).
Operating variables:-
Dilution Rate Chiller outlet temperatures Vacuum in
Rotary Filters



60

Hydro finishing unit
Purpose :-
To improve the colour and the colour 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

Parameters name Operating range
Reactors 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 H
2
flow/purity 400-450 kg/h
Licensor/ Technology IFP (France)

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


61
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.
Advantages :-
Production of API Group I LOBS of various grades
Operating variables: -
Reactor temperature
System pressure
Hydrogen circulation Rate


Vis-breaker unit

Purpose:-
To convert the high viscosity feed stock like VR/Asphalt to low
viscosity products like VB Tar/ Furnace Oil.



62
Feed Vacuum Residue/ Asphlat/ Heavy Extracts
Products


VB Tar/ FO
VB Gas oil, VB Gasolene and Fuel Gas
Unit Capacity 491000 MT/ Annum


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.

Advantages:-
Up gradation f low value feed stocks to valuable distillates
and VB Tar

Operating variables:-
Furnace coil outlet temperature
Soaker pressure
Residence time
Operating parameters:-
Furnace outlet temperature: 440 443
o
C
Back pressure: 10 12 kg/ cm
2
g.
Residence Time: 1200-1800 Second




63

NM extraction unit(NMEU)
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 (IO, HO) and DAO
Products


Raffinates of IO, HO and DAO
Extracts of IO, HO and DAO
Unit Capacity 350000 MT/ Annum
Methodology
Separation process is Extraction with a solvent named NMP (n-Methyl
Pyrollidone). 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 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 70-95 C, Bottom 60-85 C
Solvent to Feed Ratio 1.2 to 2
Licensor/ Technology IIP/ EIL



64
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.

Wax hydro finishing unit
Purpose: -


65
To improve the colour and the colour stability of De-oiled wax
obtained from SDU.
Feed De-oil wax from SDU
Products Micro Crystalline wax
Unit Capacity 15000 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

Sl. No. Parameter Operating Range
1 Make up H
2
flow 400-500 kg/h
2 System pressure 80-130 kg/cm
2
g
3 F-01 COT ~300-330 deg C
Licensor/
Technology
IFP (France)

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 vapours. The liquid part is tripped off of lighter components in a
vacuum column. Product from the column bottom is sent to storage. The
vapour part is purged to Sour fuel gas header.
Advantages:-
Production of high value Micro Crystalline Wax
Operating variables:-


66
Reactor temperature ,System pressure, Hydrogen circulation rate.



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


67
Methodology

Conversion of Wax component in Raffinate feed to Non- waxy components
Process is isomerisation of the N-Paraffins to Iso-Paraffins
N Paraffins - Waxy Nature
Iso- Paraffins - Non Waxy Nature
Feed is purified in a Hydrotreament 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.
Licensor/ Technology Exxon Mobile (USA)
Operating Variables
System pressure
Reactors Temperature
Space velocity in the Reactors
Hydrogen Circulation Rate
Parameter Operating Range
Make up H
2
flow 3500-5500 Nm
3
/h
System pressure 112.5 kg/cm
2
g
R-01 WART 320-365 deg C
R-02 WART 320-365 deg C
R-03 WART 225-260 deg C
H
2
to HC flow ratio 500-650 Nm
3
/m
3
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. Vapours 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. Vapours 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.



68