Escolar Documentos
Profissional Documentos
Cultura Documentos
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ABSTRACT
Indian Oil Corporation Limited (Indian Oil) is the largest commercial enterprise in India
with a sales turnover of Rs.150, 677 crores and profit of Rs. 4, 891 crores for the fiscal
year 2004.
Indian Oil is India’s number one company in Fortune’s prestigious listing of the
world’s 500 largest corporations, ranked 170 based on fiscal 2004 performance. It is also
the 18th largest petroleum company in the world and adjudged number one in petroleum
trading among the 15 national oil companies in the Asia-Pacific region. Indian Oil alone
accounts for 56 % petroleum product market share among PSU companies, 42% National
refining capacity and 68% downstream pipeline throughput capacity. Indian Oil group
owns and operates 10 of India’s 18 refineries with a current combined rated capacity of
54.2 Million metric tons (MMTPA). These include subsidiaries viz. Chennai Petroleum
Corporation Ltd and Bongaigaon Refinery & Petrochemicals Ltd. It owns and operates the
country’s largest network of cross-country crude and product pipelines, with a combined
length of 7,730 km with a combined capacity of 56.85 MMTPA. For the year 2004-05,
Indian Oil sold 50.1 million tones of petroleum products, including exports of 1.96 million
tones. Indian Oil’s countrywide network of over 23,000 sales points is backed for supplies
by its extensive, well spread out marketing infrastructure comprising 165 bulk storage
terminals, installations and depots, 95 aviation fuelling stations and 87 LPG bottling plants.
Its subsidiary, IBP Co. Ltd, is a stand-alone marketing company with a nationwide network
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S.No. NAME OF PROCESSING UNITS CAPACITY (MMTPA)
10 MEROX
11 ATF 1.5
12 VBN 0.058
Mathura Refinery was commissioned in the year 1982. At present it has the capacity of
processing 8.0 MMTPA of crude oil. The refinery meets the demand of Northwest region
of India including Delhi. The crude oil with low sulphur from Bombay High, imported
crude with low sulphur from Nigeria, and crude with high sulphur from Middle East
The original refinery configuration had one primary Atmospheric Vacuum unit and
the secondary units were the Vis-breaker Unit, Bitumen Unit, Sulphur Recovery unit and
Fluidized Catalytic cracking Unit. Gradually Mathura Refinery in Uttar Pradesh made
certain changes to follow the strict product specification that aroused due to environmental
considerations. The secondary units such as Once Through Hydro-cracker unit (OHCU),
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Catalytic Reforming Unit (CRU), MS quality up gradation, Diesel hydro de-sulphurisation
Unit, (DHDS), new Sulphur Recovery unit (SRU), DHDT etc were integrated in the
refinery configuration. These changes in the configuration of the Refinery were made so
Mathura Refinery has taken a number of initiatives to save the environment, public
health and also to preserve the national monuments in and around the city of Mathura. A
lot of research has been done to produce more and more clean fuels that would have
minimal negative effect on the environment. Mathura refinery has been producing highly
eco-friendly petrol and diesel for the NCT, NCR and Agra region. The Refinery enjoys the
distinction of being the first refinery in India capable of producing 100% auto fuels that
Products from this refinery are dispatched through rail, road and Mathura-Delhi –
Ambala - Jalandhar pipeline. The LPG bottling plant situated within Mathura refinery
premises bottles nearly seven million cylinder per annum for catering domestic market.
Major fertilizer industries at Kanpur, Panipat, Nangal, Bhatinda, and Kota are supplied
with Naphtha or furnace oil. Also thermal power plants of Nangal, Obra, and Badarpur get
Mathura refinery was the first in Asia and third refinery in the world to have
been honored with the coveted ISO- 14001, certification on July 22- 1996.
It was also awarded the Golden peacock national quality award 1996.
It bagged first prize in national energy conservation award in 1996 in public sector in
ministry of power.
Jawaharlal Nehru Cenetery award for achieving the best improved method of
energy conservation compared to its past best performance of 1994 & 1996.
Highest ever ATF (AVIATION TURBINE FUEL) and bitumen production of 617.6 &
430.2 TMT achieved surpassing the previous best of 613.4 TMT in 1993/94 & 425.2 TMT
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in 1993-94 respectively. Highest ever distillated yield of 73.14% on crude achieved
VISION:
A major diversified, translational, integrated energy company, with national leadership and
a strong environment conscience, playing a national role in oil security and public
distribution.
MISSION:
diversified business with focus on customer delight through value of products and services
To cultivate high standards of business ethics and total quality management for a
To help enrich the quality of life of the community and preserve ecological balance
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ACKNOWLEDGEMENT
It is great that Indian Oil Corporation Limited provides training to a large number of
disciplines.
I am thankful to Mr. C.S.Sharma, Senior Manager (MS & training) for his hospitality,
I am heartily thankful to all unit heads and all technical & Non-technical staff of
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CONTENTS
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1. ATMOSPHERIC AND VACUUM DISTILLATION UNIT (AVU)
1.1. INTRODUCTION
The ADU (Atmospheric Distillation Unit) separates most of the lighter end products such
as gas, gasoline, naphtha, kerosene, and gas oil from the crude oil. The bottoms of the
Crude oil is preheated by the bottoms feed exchanger, further preheated and
partially vapourized in the feed furnace and then passed into the atmospheric tower where
it is separated into off gas, gasoline, naphtha, kerosene, gas oil and bottoms.
100% Bombay High Crude and 100% Arab Mix crude (consisting of Light and Heavy
Stabilizer section
High Sulphur
Imported: Arab Mix, Kuwait, Dubai, Ratawi, Basra etc
1
1.3. PRODUCTS FROM CDU/VDU MAIN COLUMNS
SHORT
LONG NAME CUT RANGE ºC USAGE
NAME
Feed to
LVGO Light Vacuum Gas Oil 370-380
OHCU/RFCCU
Feed to
HVGO Heavy Vacuum Gas Oil 425-550
OHCU/RFCCU
2
1.4. STEPS OF OPERATION IN AVU PROCESS
CDU
CRUDE RECEIVING
DESALTING OF CRUDE
PREFRACTIONATOR DISTILLATION
ATOMOSPHERIC DISTILLATION
NAPHTHA STABILISATION
VDU
VACUUM DISTILLATION
50,000 m3 whereas remaining other 2 tanks are of 65,000 m3 nominal capacity). Booster
pumps located in the off-sites are used to deliver crude to the unit feed pumps. Filters are
installed on the suction manifold of crude pumps to trap foreign matter. For processing
slop, pumps are located in the off-site area, which regulate the quantity of slop into the
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crude header after filters. Provision to inject proportionate quantity of demulsifier into the
unit crude pumps suction header with the help of dosing pump is available.
required can be maintained manually by operating the bypass valve of heat exchangers.
A two-stage desalter has been designed for 99% salt removal. It is designed to use
stripped sour water for desalting which is being taken from the stripped sour water unit.
Provision to use DM water/ services water is also provided. The electric field in the
desalter breaks the emulsion and the outlet brine from the 1st stage desalter is sent to ETP
on level control.
The crude after leaving the desalter is preheated to 250 to 265 ºC. The preheated
crude is further heated and partially vapourized in Atmospheric Furnace (four furnaces
with four pass each). Heater is a box type vertical furnace with up-firing burners. 7 nos. in
each section are provided on the floor with FG and FO firing facilities. Each crude furnace
Like any conventional process heater, these heaters are also having two distinct heating
sections:
(i) A radiant section, which houses the burners and forms the combustion chamber or
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(ii) A convection section which receives heat from the hot flue gases leaving the
The convection section has 8 rows of tubes with 8 nos. tubes in each. The two rows of
shock tubes, i.e. the two rows just above the radiant section are plain tubes without studs.
The rest six rows are of extended surface type having cylindrical studs. All the convection
bank tubes are of 152mm X 8mm dimension and 5Cr 1/2 Mo material of construction. Of
these 64 tubes in the convection section, 4 no’s studded tubes are for the service of
superheating MP steam for strippers; and the rest 60 nos. tubes are for crude oil service.
Crude oil to be heated enters the convection section in four passes. From outlets of the
convection bank, it passes through crossovers provided inside the furnace into bottom coils
of the radiant section. Steam flow is of single pass to superheating coils. Provision exists to
vent out MP steam ex- super heating coils of furnaces to atmosphere through silencers.
In the radiant box, 84 nos. tubes are arranged horizontally along the height of the
two sidewalls. The tubes are of 152mm x 8mm dimension and 5 Cr 1/2 Mo material of
construction. There are 21 tubes in each pass and the pass flows are up the radiant section
to the heater outlet from top of radiant box to join the 900mm dia. Transfer line going to
crude fractionator. Heater tubes rest on wall-supported hangers and are arranged in such a
fashion as to facilitate free expansion. The floor of furnace is elevated above grade and the
hot air duct (supplying combustion air to burners) runs across the length of the furnace
below the furnace floor. The skin temperature of tubes is limited to 550 0C.
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1.6.1.2. VDU FIRED HEATER
The convection section has 13 rows of tubes with 8 nos. tubes in each. The top three rows
are for the service of superheating LP steam for vacuum column and the rest 10 rows are
for RCO service. The three rows of shock tubes, i.e. the three rows just above the radiant
section are plain tubes without studs. The next seven rows are of extended surface type
having cylindrical studs. Provision exists to vent out MP steam ex- super heating coils of
There are 5 rows of tubes in arch zone and 9 rows of tubes in radiation zone for
each pass for heating the RCO. The tubes material of construction is 9Cr 1Mo.
The floor of furnace is elevated above grade and the hot air duct (supplying
combustion air to burners) runs across the length of the furnace below the furnace floor.
The furnaces are of balanced draft type with forced draft (FD) fans to supply combustion
air and induced draft (ID) fan to take suction of the flue gases through air-preheating
The column is provided with 56 trays of which 8 are baffle trays in the stripping section.
Heated and partly vapourized crude feed coming from fired heater enters the flash zone of
the column at tray no. 46 at 355 ºC/365 ºC. Hydrocarbon vapours flash in this zone and
get liberated. Non-flashed liquid moves down which is largely bottom product, called
RCO.
MP steam having some degree of superheat is introduced in the column below tray
no. 46 at approximately 3.5 kg/cm2 (g) and 290 ºC for stripping of RCO. Steam stripping
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helps to remove lighter constituents from the bottom product (RCO). Hydrocarbon vapours
liberated by flashing move up along with the steam in the column for further mass transfer
Reduced crude oil product is collected at the bottom of the column and the
overhead vapours are totally condensed in overhead air condenser and train condenser.
This condensed overhead product is separated as hydrocarbon and water in the reflux
drum. Water is drawn out under inter-phase level control and sent to sour water drums.
1.6.3. STABILIZER
Unstable Naphtha containing Fuel Gas, LPG and Naphtha is sent to stabilizer under
Fuel Gas generated during BH/AM operation is routed to Fuel Gas Amine treatment Unit
to remove H2S before being routed to the plant Fuel Gas Distribution Header.
Hot RCO from the atmospheric column bottom at 355 ºC is mixed with slop recycle from
vacuum column, heated and partially vapourized in 8-pass vacuum furnace and introduced
to the flash zone of the vacuum column. The flash zone pressure is maintained at 115-120
mm of Hg. Steam (MP) is injected into individual passes and regulated manually. Three
injection points have been provided on each pass. This is to maintain required velocities in
the heater, which is Fuel Gas, Fuel Oil or combination fuel fired. Each cell is provided
with 10 burners fired vertically upshot from furnace floor along the centerline of the cell.
The vapourized portions entering the flash zone of the column along with stripped
light ends from the bottoms rise up in the vacuum column and are fractionated into four
side stream products in 5 packed sections. The hydrocarbon vapours are condensed in the
7
Vac Slop, HVGO, LDO and LVGO sections by circulating refluxes to yield the side draw
products.
condensed portion from the condensers are routed to the hot well from where the non-
condensable are sent to the vacuum furnace low-pressure burners or vented to the
atmosphere. Oil carried over along with the steam condensate is pumped to the vacuum
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2. VIS-BREAKING UNIT
2.1. INTRODUCTION
Vis-breaking (Viscosity Breaking or VB) is an important application of thermal cracking
used to produce Fuel Oil (FO) of lower viscosity while increasing the proportion of light
products. The vacuum residue needs further processing either through vis-breaking to
secondary processing facilities are available in 7 refineries, of which only IOC's Koyali
uses both the Hydro cracking and the Catalytic cracking method. All other refineries use
the carbon rejection process. The Vis-Breaking unit is a thermal cracking unit, designed for
processing a mixture of atmospheric and vacuum residue from 1:1 mixture of Light
Arabian and North Rumila crudes. It reduces the viscosity and pour point of heavy
petroleum fractions so that product can be sold as fuel oil. The design capacity of the plant
is 1000,000 TPA. The unit produces Gas, Naphtha, Heavy Naphtha, VB Gas Oil and Vis-
Breaker fuel oil (a mixture of VB gas oil and VB tar). A provision is also made by a small
modification to route V.B. gas oil to HSD pool over and above its original routing
conversion in the coil is about 50 to 60 %. The effluent from the furnace is routed to the
soaker drum for completion of vis-breaking reaction. The soaker effluent is quenched
before entering fractionator by injecting column bottom product (VB Tar). The quenched
effluent then enters the VB fractionator. In the bottom of the fractionator, steam is
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VB Tar is removed as the bottom product. The overhead fraction is unstable naphtha and
gas. The naphtha is stabilized and sent to MEROX unit for sweetening.
The feed stock, a mixture of atmospheric and vacuum residue, is received in the
surge drum. Pump takes suction from heat exchanger and discharges through a set of
preheat exchangers and boosters into two furnaces operating in parallel. Each furnace has
two passes and provides heat required for preheating. Feed ex furnace outlet enters soaker
drum bottom. Feed comes out from the top after getting cracked under controlled
conditions. A residence time of 1/2 hr is given in the soaker. Soaker effluent is quenched
by injecting cooled vis-breaker tar to arrest further cracking. There is also provision of
The quenched effluent enters the main fractionator where gas and gasoline are
withdrawn as overhead, gas oil as side stream and the V.B. tar as bottoms.
The overheads from the fractionator are condenser and water cooler respectively.
Uncondensed gas goes to FCC for recovery of LPG. A part of gasoline is pumped to
fractionator as reflux while the balance goes to stabilizer. Stabilized gasoline is sent to
The Heavy Naphtha (HN) is drawn from the 10th tray and stripped in HN stripper to meet
the flash point specification. It is cooled in part of air cooler and routed to HSD pool.
The gas oil is drawn from the pan of the tower and is steam stripped in the stripper
to meet flash point specification. It is cooled in air cooler and mixed with V.B. tar leaving
the unit or can be routed to HSD pool. The VB tar from the main column bottom flows
into tar stripper where gas oil fractions are evapourated as a result of pressure reduction.
The tar after cooling is partly sent to the bottom of flash fractionator, tar stripper, soaker
transfer line as quench and the rest goes to storage tank after further cooling by either
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2.3. THEORY OF VIS-BREAKING
The Vis-Breaking unit is essentially a Thermal cracking unit designed to operate at mild
conditions and to retain all the cracked light oils in the bottom product. This results in
reduction of viscosity of bottom product. In the thermal cracking reaction, heavy oil is
kept at a high temperature of a certain amount of time and this causes the larger molecules
to break up. The resulting product has a random distribution of molecular sizes resulting in
products ranging from light gas to heavy gas oil. These products are characterized as
Cracked products are unstable and form gum. The cracked naphtha has higher octane
During the cracking operation, some coke is usually formed. Coke is the end
product of polymerization reaction in which two large olefin molecules combine to form
When above reaction gets repeated several times, the end product is coke. This is
usually found inside the walls of furnace tubes and other spots where oil may remain at
high temperature and soak heat for some time. Severity of over-all reaction is determined
by residence time and temperature of cracking. Residence time in the unit can be varied by
varying charge rate and steam injection rate of DMW injection into furnace coils.
Temperature can be varied as per requirement. The cracking reaction usually does not
become evident until transfer temperature crosses 400 C. When transfer temperature
reaches 460 C; sufficient cracking of oil takes place. Gas and Naphtha are produced, the
viscosity of product is lowered and simultaneously coke deposits in the furnace tubes &
11
soaker. Increased severity results in shorter run lengths and unstable fuel oil with
sediments in it.
steel structures with outer steel casing lined with refractory material. Each of the furnaces
is independent with radiation section at the bottom. Convection section is at the top of the
radiation section and above convection section is the stack. The convection section is
provided to increase thermal efficiency of the furnace by removing further heat from the
flue gases leaving the radiation section. It is having steam super heater tubes, steam
generating tubes and oil tubes each of these numbering 6, 10 and 14 respectively. The
radiation section houses the radiation tubes numbering 30 in each pass. In this section heat
on tubes in radiation zone. Furnaces are provided with thermocouple in radiation and
convection zones for measuring tube skin temperatures, box temperatures before and after
steam coils, and flue gas to stack temperatures. Thermocouples are also provided inside
furnace tubes for measuring liquid temperatures at different points. The maximum allowed
tubes skin and box temperature in the heaters is 650 C and 750 C respectively.
There is a provision for on-stream analyzer of SO2 emission from both the stacks. The
purpose of the water injection is to maintain suitable velocity in the furnace tubes and to
minimize coking.
Effluent from these passes is gathered and sent to soaker drum. It enters from the
bottom and leaves from the top. Thermal cracking of the feed, which is initiated in the
furnace, gets completed in soaker drum. Residence time of the order of half an hour is
given in soaker.
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To arrest cracking reactions, materials from each pass of the two furnaces are individually
quenched by the injection of cooled VB tar at 223oC. To increase turbulence and to prevent
coke deposit in the coils, there is provision to inject steam in each pass. The purpose of the
water injection is to maintain suitable velocity in the furnace tubes and to minimize coking.
420 C. From the column, gas & gasoline are separated as overhead, gas oil as side stream
and the VB tar as bottoms. The fractionator has 26 valve trays and one blind tray. Feed
The overhead vapours from the column are condensed and cooled in heat
exchangers. The liquid vapour mixture is separated in the reflux drum. Gasoline from flash
fractionator is picked up by reflux pumps and partly pumped to column top as reflux. The
remaining gasoline is routed to stabiliser under reflux drum level controller, which is
cascaded with flow controller. The sour water is drained from the drum boot under
interface level controller and routed to sour water stripper. Main reflux drum and its water
boot are having level glasses. Uncondensed gas from Gas oil stripper goes to FCC/AVU
furnaces / Flare. Column top pressure is around 4.5 kg/cm2 (g). Column overhead line is
The heavy naphtha at a temperature of about 170 C is withdrawn from tray no. 10
under level controller. It is stripped in the stripper to maintain its flash point. The heavy
naphtha is routed to HSD. Gas oil at a temperature of about 260 C is withdrawn from the
blind accumulator tray under tray level controller. It is steam stripped in the stripper to
maintain its flash point. Vapour from stripper top returns back to column just above the
blind accumulator tray. A part of gas oil from air cooler is used for washing VB tar filters.
Blind accumulator tray and stripper are provided with level glasses.
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To remove extra heat and to maintain desired temperature profile in column, a portion of
gas oil from blind tray is taken and pumped in two streams. One stream is used as heating
media in steam generator where it is cooled from 260 C to 214 C. The second stream
supplies re-boiling heat to stabilizer re-boiler and gets cooled from 260 C to 215 C. To
protect column bottom against coking, cooled VB tar at 225 C is injected into bottom as
quench. Gas oil vapours from top of stripper get condensed in air cooler and go to reflux
drum. Safety valve is provided to release gas and protect the vessel from over pressure.
Tar is cooled from 351 C to 225 C in feed exchangers and further cooling to 214
C is done. Pumps are having two filters in the suction line with gas oil flushing facilities.
Only one filter is kept in service while the other remains as spare. Cooled VB tar is partly
used as quench to
3. Gas oil stripper bottom should be protected against coking. Bottom temperature
is maintained at 351C.
VB tar is then cooled in boiler feed water exchanger from 232C to 210C. It is further
2.6. STABILIZER
Un-stabilized gasoline from reflux drum is picked up by reflux pump and then it is pumped
to stabilizer through stabilized gasoline exchanger. In heat exchanger, feed is heated from
43 C to 120 C while stabilized gasoline is cooled from 180 C to 120C. The column has
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The overhead product at 60 C goes to water condensers. The condensed liquid is collected
in the reflux drum. Uncondensed gas from the drum goes to FCC/unit fuel gas header.
Pressure at the drum is maintained around 8.4 kg/cm2 (g). In case FCC is shutdown, gas is
burnt in furnaces via gas knock out drum. Column overhead has working and controlled
When feed rate is increased, residence time in furnace coil and column reduces causing
reduction in severity of cracking reaction resulting in raising the viscosity and pour point
of VB tar and in turn reduction of coke lay down in furnace coils & the column.
TEMPERATURE
At constant feed rate, if transfer temperature is raised the amount of cracking increases.
The VB tar quench reduces the temperature at the column outlet and stops further cracking.
This quench helps in reducing the tendency to lay down coke in the transfer lines and
columns.
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2.7.4. FRACTIONATOR PRESSURE
A lower pressure causes more vapourisation resulting in heavier naphtha and gas oil.
Higher pressure makes naphtha and gas oil lighter. VB tar viscosity also goes down.
Lowering the top temperature reduces initial boiling point and flash point of gas oil. The
yield of naphtha comes down. Raising the top temperature will increase the FBP of gas oil
BOTTOM
In order to reduce coke formation in the fractionator bottom, cooled VB tar at 225 C is
BOTTOM
To minimise coke formation in tar stripper, cooled VB tar at 225 oC is returned as quench
to its bottom.
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2.7.8. STABILISER TEMPERATURE AND PRESSURE
The stabiliser removes most of butanes and lower hydrocarbons from unstable Naphtha.
These are removed as gas from the stabiliser overhead. Higher top temperature makes
overhead gas heavies. On the other hand, lower top temperature gives lighter gas. Lower
column pressure causes higher amount of hydrocarbons to be carried into the fuel gas
system.
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3. FLUID CATALYTIC CRAKING UNIT (FCCU)
3.1. INTRODUCTION
In the newer designs for Fluid Catalytic Cracking Unit, cracking takes place using a very
active zeolite-based catalyst in a short-contact time vertical or upward sloped pipe called
the "riser". Pre-heated feed is sprayed into the base of the riser via feed nozzles where it
contacts extremely hot fluidized catalyst at 1230 to 1400 °F (665 to 760 °C). The hot
catalyst vapourizes the feed and catalyzes the cracking reactions that break down the high
molecular weight oil into lighter components including LPG, gasoline, and diesel. The
catalyst-hydrocarbon mixture flows upward through the riser for just a few seconds and
then the mixture is separated via cyclones. The catalyst-free hydrocarbons are routed to a
main fractionator for separation into fuel gas, LPG, gasoline, light cycle oils used in diesel
During the trip up the riser, the cracking catalyst is "spent" by reactions which
deposit coke on the catalyst and greatly reduce activity and selectivity. The "spent" catalyst
is disengaged from the cracked hydrocarbon vapours and sent to a stripper where it is
contacted with steam to remove hydrocarbons remaining in the catalyst pores. The "spent"
catalyst then flows into a fluidized-bed regenerator where air (or in some cases air plus
oxygen) is used to burn off the coke to restore catalyst activity and also provide the
necessary heat for the next reaction cycle, cracking being an endothermic reaction. The
"regenerated" catalyst then flows to the base of the riser, repeating the cycle.
The gasoline produced in the FCC unit has an elevated octane rating but is less
chemically stable compared to other gasoline components due to its olefin profile. Olefins
in gasoline are responsible for the formation of polymeric deposits in storage tanks, fuel
18
ducts and injectors. The FCC LPG is an important source of C3-C4 olefins and isobutane
that are essential feeds for the alkylation process and the production of polymers such as
polypropylene.
In this process Heavy Gas Oil cut (Raw Oil) from Vacuum Distillation Section of
AVU is catalytically cracked to obtain more valuable light and middle distillates. The
present processing capacity of the unit is about 1.48 MMT/Yr. It consists of the following
sections:
Cracking section
Catalytic section,
CO boiler
The unit is designed to process two different types of feed i.e. Arab Mix HVGO and
lighter products. This can be accomplished either thermally or catalytically. The catalytic
process has completely superseded thermal cracking as the catalyst helps the reactions to
take place at lower pressures and temperatures. At the same time, the process produces a
higher octane gasoline, more stable cracked gas and less of the undesirable heavy residual
product. The process is also flexible in that it can be tailored to fuel oil, gas oil operations
producing high yields of cycle oils or to LPG operations producing yields of C3-C4
fraction.
The fluid Catalytic Cracking process employs a catalyst in the form of minute
spherical particles, which behaves like a fluid when aerated with a vapour. This fluidized
19
catalyst is continuously circulated from the reaction zone to the regeneration zone. The
catalyst also transfers heat carried with it from one zone to the other viz. in the vessels
reactor and regenerator. The reaction and regeneration zones form the heart of the
Feed to the FCC Unit is gas oils obtained by vacuum distillation of long residue
from the crude distillation unit. In our unit the vacuum cut boiling in the range 380-530 C
will be used as feedstock to the FCC Unit. Carbon content in the feedstock should be
limited to 0.5% by wt. maximum. This carbon content increases with heavier charge stock.
Catalyst section consists of the reactor and regenerator together with the standpipes and
riser form the catalyst circulation circuit. The catalyst circulates up the riser to the reactor,
down through the stripper to the regenerator across to the regenerator standpipe and back
to the riser. The vertical riser is in fact the reactor in which the entire reaction takes place.
The reactor is a container for cyclone separators at the end of vertical riser.
Fresh feed after heat exchange and heating up to 340-360 C in a feed pre-heater
enters through 4 fresh feed nozzles to the riser. Recycle is introduced by 2 HCO and 2
Slurry feed nozzles to the riser. The feed is vapourized and raised to the reactor
temperature by the hot catalyst flowing upward through the riser. Cracking reactions start
immediately as the gas oil comes into contact with the hot catalyst. These reactions
continue till the oil vapours are separated from the catalyst in the reactor. T head separators
mounted on top of the riser separate the catalyst from the oil vapours. This separation is
required to prevent secondary reactions, which will result in higher gas production.
Entrained catalyst and hydrocarbon vapours, after cracking, flow upwards and pass
through two cyclone separators attached to top of the reactor. These cyclones remove most
of the entrained catalyst. Oil vapours containing a small quantity of catalyst pass overhead
20
Coke is deposited on the catalyst in the reaction zone. The spent catalyst flows downwards
into the stripping section of the reactor. After steam stripping to remove oil vapours from it
the catalyst flows from the reactor standpipe to the regenerator through a slide valve in the
regenerator, the coke is burnt off, oxygen for burning being supplied by an air blower. Air
from the blower is uniformly given to the regenerator through a pipe grid at its bottom.
The heat of combustion raises the catalyst temperature to more than 600 C. Most of the
heat in the catalyst is given to the feed in the reactor riser to raise it to the reaction
temperature and to provide the heat of reaction. The regenerated catalyst from the
standpipe flows into the riser through a slide valve to complete the catalyst circulation
cycle. Catalyst particles in the flue gas leaving the regenerator are separated at the top of
regenerator by three sets of two-stage cyclones. The flue gas contains both CO and CO2 as
carbon is burnt off partly to CO and partly to CO2 in the regenerator. The sensible and
chemical heat in flue gas is utilized to generate steam in CO Boiler. The flue gas 'is passed
through' the orifice chamber & regenerator. Pressure is controlled by double disc slide
reducing the pr. drop across slide valve, operating life of slide valve is greatly extended by
particles, which behaves like a fluid when aerated with a vapour. This fluidized catalyst is
Feed to the FCC Unit is gas oils obtained by vacuum distillation of long residue
from the crude distillation unit. In our unit the vacuum cut boiling in the range 380-530°C
is used as feedstock to the FCC Unit. Conradson carbon content in the feedstock should be
21
limited to 0.5% by wt. maximum. Metal contaminants of the feedstock are also to be
Catalyst section consists of the reactor and regenerator together with the standpipes
and riser form the catalyst circulation circuit. The catalyst circulates up the riser to the
reactor, down through the stripper to the regenerator across to the regenerator standpipe
and back to the riser. The vertical riser is in fact the reactor in which the entire reaction
takes place. The reactor is a container for cyclone separators at the end of vertical riser.
Fresh feed after heating up to 350 C in a feed pre-heater along with recycle
streams enters the base of the riser. In the riser the combined feed is vapourized and raised
to the reactor temperature by the hot catalyst flowing upward through the riser. Cracking
reactions start immediately as the gas oil comes into contact with the hot catalyst.
Entrained catalyst and hydrocarbon vapours, after cracking, flow upwards and pass
through two cyclone separators attached to top of the reactor. These cyclones remove most
of the entrained catalyst. Oil vapours containing a small quantity of catalyst pass overhead
Coke is deposited on the catalyst in the reaction zone. The spent catalyst flows
downwards into the stripping section of the reactor. After steam stripping to remove oil
vapours from it the catalyst flows from the reactor standpipe to the regenerator through a
slide valve in the regenerator, the coke is burnt off, oxygen for burning being supplied by
an air blower. The heat of combustion raises the catalyst temperature to more than 600 C.
Most of the heat in the catalyst is given to the feed in the reactor riser to raise it to the
reaction temperature and to provide the heat of reaction. The regenerated catalyst from the
standpipe flows into the riser through a slide valve to complete the catalyst circulation
22
cycle. Catalyst particles in the flue gas leaving the regenerator are separated at the top of
regenerator by three sets of two-stage cyclones. The flue gas contains both CO and CO2 as
carbon is burnt off partly to CO and partly to CO2 in the regenerator. The sensible and
The unit is designed for use of high ZEOLITE catalyst, which is microspheriadical in
fractionated into wet gas and un-stabilized gasoline overhead products, heavy naphtha, and
light cycle oil as side products. Heavy cycle oil drawn from the column is totally recycled
along with the feed after providing for the recycle stream to the column.
The column bottom slurry containing a small quantity of catalyst is sent to a slurry
settler. From the settler bottom, the thickened slurry is recycled back to the riser for
recovering catalyst and further cracking. From the top of slurry settler, clarified oil product
is taken out after cooling, which goes for blending in Fuel Oil.
23
3.5. GAS CONCENTRATION SECTION
The wet gas from the fractionator overhead receiver is compressed in a two-stage
centrifugal compressor and sent to a high-pressure (HP) receiver after cooling. Gas from
the HP receiver is sent to the Primary Absorber for recovery of C3's and heavier
components by absorption with stabilized gasoline taken from the debutanizer column
bottom and un-stabilized gasoline from main column overhead receiver. Rich gasoline
from absorber bottom is recycled back to the HP receiver. The stripped gasoline is further
stabilized in the debutanizer removing C3 and C4 components from it as cracked LPG and
bottom product as stabilized FCC gasoline. Both LPG and gasoline are MEROX treated
3.6. CO BOILER
The flue gas leaving the regenerator via orifice chamber contains 8-13% carbon monoxide,
the rest being inert like nitrogen, steam, carbon dioxide, etc. In the CO Boiler, flue gas is
burnt with air converting carbon monoxide to carbon dioxide, thus releasing the heat of
combustion of CO in the boiler. This heat as well as the sensible heat in flue gas available
4.1. INTRODUCTION
The MEROX process efficiently and economically treats petroleum fractions to remove
objectionable disulfides (MEROX sweetening). This process can be used to treat liquids
such as liquefied petroleum gases (LPG), natural-gas liquids (NGL), naphtha, gasoline,
24
kerosene, jet fuels, and heating oil. It can also be used to treat gases such as natural gas,
refinery gas, and synthetic gas in conjunction with conventional pre-treatment and post-
treatment processes.
distillation may contain hydrogen sulfide and mercaptans, the extent of which mainly
depends upon the type of crude processed. Similar products from secondary processes such
as FCC also contain hydrogen sulfide and mercaptans to a greater degree compared to
meet specifications on corrosion rate. The specification for LPG, gasoline, Kerosene and
ATF include copper strip corrosion test which is a measure of rate of corrosion on copper
containing materials. Mercaptans are substances with obnoxious odor and, therefore, in
order to handle and store them, mercaptan level will have to be brought down to an
acceptable odor level. The specifications of above products include 'Doctor Test' which
must be negative and is generally related to the extent of mercaptan present. Hydrogen-
sulfide can be easily removed by washing with dilute caustic solution. However, for
Strong alkali-wash
Copper sweetening
Doctor sweetening
MEROX process
Hydro desulphurization
Alkali-wash is effective only if low molecular weight mercaptans are involved. Hydro
required. Both investment and operating costs are higher in case of hydro desulphurization.
25
4.2. MEROX PROCESS DESCRIPTION
MEROX process equipment
Pretreatment
Extraction section
Sweetening
Post treatment
MEROX catalysts
The MEROX process licensed by M/S Universal Oil Products Co., (UOP), USA, is for the
chemical treatment of LPG, gasoline and distillates to remove mercaptans into disulfides.
The removal of mercaptans may be either partial or full. The chemical treatment is based
The oxidation is carried out in the presence of an aqueous alkaline solution such as sodium
Low molecular weight mercaptans are soluble in caustic solution and therefore
when treating LPG and light gasoline fractions, the process can be used to extract
mercaptan to the extent, they are soluble in caustic. Extraction of mercaptan reduces the
disulfides without removing any sulphur from the treated stock in which case the operation
26
4.2.1. PRETREATMENT
Petroleum fractions may contain hydrogen sulfide and stocks boiling higher than 180°C
may also contain naphthenic acids. Hydrogen sulfide is not a catalyst poison as such, but
will dilute the caustic containing MEROX catalyst by reacting with caustic. Further it
blocks some of the catalyst activity sites slowing down the normal reaction and also
consumes part of the oxygen available. Hence, it is recommended that hydrogen sulfide is
removed by washing with dilute alkali solution before the distillate is sent to reactor for
treatment.
Naphthenic acids also interfere with treating operations and must be removed prior
to treatment. The reactor contains caustic and if naphthenic acids are not removed, they
form sodium naphthenates, which coat the catalyst and block the pores. For removal of
naphthenic acids, the procedure used is to wash with dilute caustic. Dilute caustic is used
depending on the acidity of stock treated. The haze can easily be removed by coalescing
Feedstock, where carry-over of water from distillation units can be expected must
be passed through a coalescer for removal of suspended water prior to caustic wash, which
As previously stated, low molecular weight mercaptans are caustic soluble and can easily
favored by:
Type of mercaptans, viz. normal mercaptans are easily extractable, tertiary mercaptans
This being a reversible reaction the degree of completion of reaction is governed by normal
equilibrium laws.
The sodium mercaptide is readily oxidized to disulfide in the presence of MEROX catalyst
as shown:
This is not a reversible reaction and the reaction rate is sped up by:
The oxidation of mercaptides is carried out in oxidizer in the presence of MEROX catalyst.
The disulfides oil, which is formed, separates out from caustic, as it is insoluble in caustic.
Caustic can be reused for extraction. The presence of MEROX catalyst in extraction
caustic does not however, affect the amount of mercaptans extracted and extraction is
28
4.2.3. SWEETENING
stream to disulfide sulphur without actually reducing sulphur content of treated stock. The
sweetening process is based on the ability of MEROX catalyst to promote the oxidation of
mercaptans to disulfide using air as the source of oxygen. The reaction is as follows:
As can be seen from reactions, the oxidation is carried out only in the presence of alkali
solution.
The Sweetening can be accomplished either as solid bed sweetening, where the
hydrocarbons and caustic are simultaneously controlled over a solid support impregnated
with MEROX catalyst or as liquid-liquid sweetening, where hydrocarbon, air and caustic
charcoal impregnated with MEROX catalyst and kept wet with caustic solution.
solution and pumping ammonia solution over charcoal. Air is injected ahead of reactor and
in the presence of MEROX catalyst the mercaptans are oxidized to disulfide. The reactor is
circulated from the settler over the catalyst bed to wet the charcoal.
For liquid-liquid sweetening, the most common type of mixer used is the orifice
plate mixer, which is a vessel, fitted with a series of plates with orifices. The vessel
provides adequate residence time and the orifice plates create enough turbulence to bring
29
about the intimate contact between hydrocarbons, caustic, catalyst and air. The higher the
molecular weight or the more highly branched the mercaptan is, the more difficult it is to
accomplish necessary mixing. Hence heavy gasoline and Kerosene may have to be treated
The product from the MEROX reactor will at times contain caustic haze. Post treatment is
required if the product is to go to storage, clear and bright. In most cases provision of
caustic settler and sand filter is adequate to remove caustic haze. However, for treatment of
ATF, which has to meet stringent specifications caustic must be removed by water wash
after caustic settling. Water wash removes entrained caustic as well as water soluble
surfactants. Water wash is followed by a salt filter to remove entrained water and part of
the dissolved water. This may be followed by clay filter to remove copper and water
There are two types of MEROX catalyst, each one being used for specific service. Catalyst
FB is to be used on units equipped with solid bed sweetening reactors. Catalyst WS is used
for liquid-liquid sweetening in mixers. This is a caustic dispersible catalyst. This is also
30
5. CONTINUOUS CATALYTIC REFORMING UNIT (CCRU)
5.1. INTRODUCTION
A catalytic reforming process converts a feed stream containing paraffins, Olefins and
reformate. Reformate produced by this process has a very high octane rating. Significant
idea of a Catalytic Reforming Unit is to have RON (Research Octane Number) as high as
possible at the same time keeping the Olefins, Benzene & Aromatics under the specified
limits. The different types of reformers are classified as a fixed-bed type, semi-regenerative
type, cyclic type and the continuous regenerative type. This classification is based on the
ability of the unit to operate without bringing down the catalyst for Regeneration. During
the regeneration process, the refinery will suffer production loss. In the Continuous
Catalytic Reforming unit, the reactors are cleverly stacked, so that the catalyst can flow
under gravity. From the bottom of the reactor stack, the 'spent' catalyst is 'lifted' by
nitrogen to the top of the regenerator stack. In the regenerator, the above mentioned
different steps, coke burning, oxychlorination and drying are done in different sections,
segregated via a complex system of valves, purge-flows and screens. From the bottom of
the regenerator stack, catalyst is lifted by hydrogen to the top of the reactor stack, in a
special area called the reduction zone. In the reduction zone, the catalyst passes a heat
exchanger in which it is heated up against hot feed. Under hot conditions it is brought in
contact with hydrogen, which performs a reduction of the catalyst surface, thereby
restoring its activity. In such a continuous regeneration process, a constant catalyst activity
can be maintained without unit shut down for a typical run length of 3 - 6 years. The
31
purpose of the CCR unit is to produce a high octane no. reformate. The octane no. of the
gasoline coming from the AVU is around 66, whereas the required value of the octane no.
is 87, 88 and 93. The whole CRU can be divided into three subunits as:
This unit has been designed to split SR naphtha (144 MT/hr for BH and 95 MT/hr for AM)
to C5-80 oC and 80-115 oC cut. Due to the restriction on Benzene content in the final
product (motor spirit), the IBP of the heavier cut is raised to approximately 105 oC. NSU
can be operated with naphtha directly from AVU (hot feed) and from OM&S (Cold feed),
it can also be operated using both the feed simultaneously. For removal of benzene, the
gasoline from storage tanks and CDU is sent to a column, containing 40 valve trays, which
is called naphtha splitter. The bottom product of naphtha splitter is sent to the NHU.
nitrogen, halogens, oxygen, water, olefins, di-olefins, arsenic and metals) from the feed
that would otherwise affect the performance and lifetime of reformer catalyst. This is
achieved by the use of selected catalyst (nickel, molybdenum) and optimum operating
In this unit, the naphtha coming from the NSU is mixed with H2 which comes from
the reforming unit. This mixture is heated to 340 OC in the furnace and then passed to the
32
In the reactor, there are two beds of catalyst. In one bed, the unsaturated hydrocarbons are
converted to saturated hydrocarbons and in the second bed impurities like N, S, and O are
converted to NH3, H2S and H2O respectively. The effluent of the reactor is sent to stripper
section to eliminate the light end, mainly the H2S and moisture from the reformate feed.
The light gases from the top of stripper are sent to amine wash unit. There is a reboiler
attached to the bottom of the stripper, which maintains the heat requirement. The bottom
hydrotreater stripper after heat exchanger. The filters must be provided for the protection
of the welded plate exchanger. Feed is filtered to remove any foreign particles. At the D/S
of the feed filter, chloriding agent and water injection are done. CCl4 solution of 1% in
reformate is dosed by pump. Dosing @ 1 ppm wt CCl4 in feed is done when continuous
regeneration unit is down. Water injection (not on regular basis) is done to maintain Cl-OH
Feed mixed with recycle H2 stream gets preheated in PACKINOX exchanger from
91C to 451C by the effluent from 3rd Reactor which gets cooled down from 497 C to
98C.
Due to the endothermic nature of the reforming reactions, the overall reforming is
achieved in stages with inter stage heater provided to raise the temperature. There are three
Reactors (15R-1, R-2 & R-3) each provided with reaction heater.
33
5.2. REACTORS
In the reactors, the feed contacts the reforming catalyst which is divided approximately in
the ratio 15: 30: 55. In the CCR process, the catalyst circulates continuously in reactors, in
the space between the external grid and the central pipe from the top to the bottom, from
one reactor bottom to the top of the next one, from the last reactor to the regeneration unit
for regeneration. From the regeneration unit, the regenerated catalyst returns to the first
reactor.
Each reactor is a vertical cylindrical vessel with spherical heads. It is equipped with
one inlet & one outlet nozzle for feed & effluent respectively. Catalyst enters the reactor
through 12 nos. of 3" pipes, flows through the space between external grid and the central
pipe from top to bottom and exits through 12 nos. of 2"pipes, slow moving bed of
bimetallic catalyst and exits through the outlet nozzle at the bottom. The radial flow of feed
is achieved by directing the flow through external grid to catalyst bed & exit is made to
central outlet collector pipe. Gas tight baffle is provided on the outlet pipe to avoid short-
cooler to 65 C and then by trim cooler to 45C before entering the separator. The
separated gas is compressed in the recycle gas compressor and a part is recycled to the
reactors. The remaining gas is routed to a re-contacting section to improve hydrogen purity
6.1. INTRODUCTION
Hydro Cracking Unit is designed for 1.2 MMT/year (165.6 m³/hr, 25,000 BPSD). The
objective of the Hydro Cracking Unit is to produce middle distillate fuel of superior
34
quality. The unit is designed to process two different types of feed i.e. Arab Mix HVGO,
Bombay High HVGO. All the H2S will be removed by absorbing in DEA.
Reaction Section
Fractionation Section
The feed control system allows the operator to control the ratio of Arab Mix and Bombay
High VGOs in order to set the relative rates of each. The preheated and filtered oil feed is
combined with a preheated mixture of make-up hydrogen from the make-up hydrogen
compression section and hydrogen-rich recycle gas from the recycle gas compressor in a
gas-to-oil ratio of 845 Nm3/m3. The combined oil and gas streams are heated in the
feed/effluent exchangers and then further heated to the desired reactor inlet temperature in
the reactor feed furnace. The reactor system contains one reaction stage consisting of two
reactors in series in a single high-pressure loop. The lead and main reactors contain hydro
treating and hydro cracking catalyst (Si/Al with Ni-Co-Fe) for denitrification,
The reactor effluent is initially cooled by heat exchange with the VGO feed and
then by heat exchange with recycle gas and with the product fractionator feed. The effluent
35
After the effluent stream is cooled, it is sent to the HHPS at 210°C to separate the reactor
products from the excess hydrogen and gases formed in the reactors. Liquid from the
HHPS flows to the power recovery turbine (PRT), where it is let down in pressure before
The effluent vapour separated in the HHPS contains most of the H2, H2S, NH3, and
light hydrocarbon gases. The effluent vapour is cooled by heat exchange with the CLPS
liquid, where it exchanges heat with the reactor feed gas. Subsequently it enters the
effluent vapour air cooler. Cooled reactor effluent vapour, condensed light hydrocarbons,
and sour water enter the CHPS at 65C. Hydrogen-rich recycle gas separates from the oil
and water phases, exits the CHPS, and enters the recycle gas loop. Liquid hydrocarbon is
drawn off and is sent to the CLPS. The sour water, containing about 7 wt % ammonium bi-
sulfide, is drawn from the separator bottom and sent to sour water stripping.
Hydrogen-rich recycle gas is sent to a High Pressure H2S absorber. The H2S is
removed from the recycle gas by being absorbed by an amine solution (25 wt % Di-ethanol
amine) flowing countercurrent to the recycle gas. The lean amine is heated by heat
exchange with diesel product and then by steam. After heating, the lean amine is sent to a
surge drum before being pumped up to system pressure. The H2S-rich amine stream from
the bottom of the absorber is let down in pressure and sent to a flash drum and amine
regeneration unit. The H2S absorber vapour flows to Porta Separator and then to the
The hydrogen-rich vapour from the knockout drum flows to the recycle compressor
(Centrifugal Compressor) that restores the pressure losses accumulated as the gas flows
Part of the compressed recycled gas is used as quench gas and the remaining recycle gas
36
6.2.2. FRACTIONTATION SECTION
The fractionation section consisting of the fractionator, side cut strippers, and heat
The reaction products recovered from the column are Sour Gas (Off gas), Unstable Light
Naphtha, Heavy Naphtha, Kerosene, Diesel and FCC Feed. The fractionator off-gas and
unstable light naphtha are sent to the light ends recovery section for recovery of LPG and
6.2.3. DE-ETHANISER
The de-ethaniser remove light ends (C2), H2S, and water from the light naphtha and LPG.
Feed enters the top of the column. The feed to the de-ethaniser comes from the combined
liquid stream leaving the de-ethaniser reflux drum and is pumped to the top of the de-
ethaniser.
7.1. INTRODUCTION
DHDS (Diesel hydro desulphurization unit) is set up for the following purposes:
To produce low sulphur diesel (0.25 w/w %) as per govt. directive w.e.f. Oct. 1999.
Feed consists of different proportion of straight run LGO, HGO, LVGO and TCO. Mainly
37
48% SR LGO, 24% SR HGO, 8% SR LVGO, 20% TCO
The DHDS unit treats different gas oils from various origins, straight run or cracked
olefins), Aromatics, Sulfur compounds and Nitrogen compounds. Sulfur and nitrogen
The purpose of DHDS Unit is to hydro-treat a blend of straight run gas oil and
cracked gas oil (TCO) for production of HSD of sulfur content less than 500 ppm wt.
This H2S removal is achieved by means of a continuous absorption process using a 25%
In addition to the desulphurization, the diolefins and olefins will be saturated and a
denitrification will occur. Denitrification improves the product stability. The hydrogen is
supplied from the hydrogen unit. Lean amine for absorption operation is available from
Amine Regeneration Unit (ARU). Rich Amine containing absorbed H2S is sent to ARU for
amine regeneration.
7.2. CATALYSTS
Catalysts used for this process are HR-945 and HR-348/448.The HR-945 is a mixture of
nickel and molybdenum oxides on a special support. Nickel has been selected because it
boosts the hydrogenating activity. The HR-348 and HR-448 are desulphurization catalysts;
it consists of cobalt and molybdenum oxides dispersed on an active alumna. Its fine
Different catalysts based on Nickel and Molybdenum Oxide are used to enhance
38
7.3. PROCESS DESCRIPTION
Feed can be received from three sources:
Feed from above sources pass through feed filter and is received in feed surge drum. The
level of feed surge drum is controlled by controller, which can be cascaded with feed from
storage or feed from AVU. Water if any shall be collected in the water boot of surge drum
and its discharge passes through pre-heat exchangers. Hydrogen recycle joins the feed
before heat exchangers. Feed then enters heater in four passes and then to reactor. The
reactor has two catalyst beds. Recycle gas quench is given in between reactor catalyst beds
to control inlet temperature of lower bed. Reactor effluent from reactor bottom is utilized
for preheating of feed in exchangers. The other part of reactor effluent is utilized to preheat
the stripper feed in exchangers. All the effluent join and enter to reactor effluent cooler and
The vapour phase from CHPS is sent to high-pressure amine absorber through
high-pressure amine knockout drum. This gas is treated with lean DEA solution in high-
pressure amine absorber. The treated gas goes to recycle gas compressor through recycle
The liquid hydrocarbon under level control from CHPS is sent as feed to stripper
after preheating heat exchanger. Water from CHPS boot is sent partially to water drum and
Sweet diesel from bottom of stripper exchanges heat with stripper feed in
exchangers and is pumped to storage under stripper bottom level control before routing to
39
storage tank. Diesel is cooled in air cooler and water cooler, then passed through coalescer
desirable reactions:
Hydrodesulphurization
Hydro cracking
Coking
7.4.2. TEMPERATURE
The reaction temperature must be kept as low as possible because the most desirable
Hydrodesulphurization
40
8. HYDROGEN GENERATION UNIT (HGU) - I
The Hydrogen plant is designed for production of 34,000 MTPY of Hydrogen. Process
licensor for HGU is HTAS, Denmark. The plant is divided into 3 sections.
Desulphurization
Reforming
CO-Conversion
8.1. FEED
The hydrogen generation unit can be fed either by naphtha or natural gas. The naphtha feed
is pressurized to about 35 Kg/cm2g by one of the naphtha feed pumps and sent to the
desulphurization section.
The pressurized feed is mixed with recycle hydrogen from the hydrogen header.
The liquid naphtha is evapourated to one of the naphtha feed vapourizers. The hydrocarbon
feed is heated to 380°-400 OC by heat exchange with superheated steam in the naphtha
feed pre-heater.
8.2. DESULPHURIZATION
The desulphurization takes place in two steps. The first catalyst in the desulphurization
R1 – S – R2 + 2H2 → R1 – H + R2 – H + H2S
41
Having passed the hydrogenation catalyst in the first reactor the hydrogenated process feed
is sent to the sulphur absorbers. Here the H2S formed is absorbed by the ZnO absorption
catalyst.
The concentration of sulphur leaving the absorbers shall be lower than 50 ppm.
8.3.1. PRE-REFORMER
The mixture of gas and steam (the process gas) is heated to approximately 490 OC. The
preheated process gas passes the pre-converter, where all higher hydrocarbons are
feed preheat coil before it is sent to the tubular reformer containing 126 catalyst tubes
maintained at desired temperature. The reformer effluent leaves the tubes at a temperature
of approximately 930 ° C.
42
9. BITUMEN BLOWING UNIT (BBU)
9.1. INTRODUCTION
Asphaltic bitumen, normally called "bitumen" is obtained by vacuum distillation or
The bitumen thus obtained has properties which are derived from the type of crude
oil processed and from the mode of operation in the vacuum unit or in the solvent de-
asphalting unit. The grade of the bitumen depends on the amount of volatile material that
remains in the product: the smaller the amount of volatiles, the harder the residual bitumen.
The blowing process for bitumen preparation is carried out continuously in a blowing
column. The liquid level in the blowing column is kept constant by means of an internal
draw-off pipe. This makes it possible to set the air-to-feed ratio (and thus the product
quality) by controlling both air supply and feed supply rate. The feed to the blowing unit
(at approximately 210 0C), enters the column just below the liquid level and flows
downward in the column and then upward through the draw-off pipe. Air is blown through
the molten mass (280-300 0C) via an air distributor in the bottom of the column. The
bitumen and air flow are countercurrent, so that air low in oxygen meets the fresh feed
first. This, together with the mixing effect of the air bubbles jetting through the molten
mass, will minimise the temperature effects of the exothermic oxidation reactions, local
continuously from the surge vessel under level control and pumped to storage through
43
Air residue having boiling point 530oC (TBP) is obtained from North Rumaila crude. Air
condensed oil. Bitumen is a colloidal solution of asphaltenes and associated high molecular
gums in the medium formed by oils and low molecular gums. Asphaltene content in the
bitumen influences its solidity and softening point. The higher the asphaltene content, the
more solid is the bitumen. Gums increase bitumen binding properties and elasticity.
from tanks. The hot feed goes to reactors at 200-210oC in two parallel streams. Flow
control valves control feed flow to individual reactors. As refinery would be processing
both Imported and Bombay high crude in blocked out cyclic operation, the unit will not get
hot feed during the period AVU processes indigenous crude. To avoid shut down of BBU
under such circumstances or when VDU is down the unit will be supplied cold feed from
the tanks.
as well as finished bitumen. The pumps take feed from the tanks and discharge it through
44
BITUMEN FURNACE
It is a natural draft furnace with convection and radiation sections. The convection section
forms rectangular box while radiation zone is cylindrical in shape. The two sections are
having horizontal and vertical feed coils respectively. Pumps supply cold feed to furnace at
temperature of 150-180oC. Furnace has two coil passes. Provision also exists to operate the
furnace as a simple coil pass while operating at low turndown ratio. Feed enters through
convection zone at the top and control valves control flow of each stream. The furnace is
provided with one oil-cum-gas burner at its base. The feed first picks up heat from the flue
gases in the convection section and then it is heated in the radiation zone coils. The feed is
heated up to 230oC. The two passes join together at the outlet of furnace and are routed to
9.2.3. REACTORS
Compressed air at 80oC is supplied through spargers provided at the reactor bottom.
Oxidation of the residue is carried out at a temperature of about 240-260oC. In the vapour
space there is steam injection facility to avoid after burning of gases coming from the
reactor. Oxygen content in the reactor overhead gas is not allowed to exceed 5%.
45
9.2.5. REACTOR OVERHEAD SYSTEM
From the top of the reactors the hydrocarbon vapours, steam and unreacted air at about
220-240oC go to air coolers where they are cooled to 170oC. The combined vapour-liquid
mixture from the cooler goes to oxidation gas separators, which operate in parallel.
170oC is periodically pumped through another cooler. Oil is cooled to 80oC and sent to
FFS tanks/IFO tanks. The uncondensed gas at 170oC passes through demister pads in the
overhead lines. Liquid separated is drained to OWS. The two gas streams join a common
INCINERATOR
Overhead gases from separator enter the incinerator from the top where they are burnt at a
temperature of 700-1000oC.
46
10. AMINE RECOVERY UNIT (ARU)
10.1. INRODUCTION
Diethanol amine almost saturated with H2S (rich amine) and received at battery limit from
DHDS, FCC, OHCU unit is processed in unit ARU to separate out H2S and amine solution
(lean amine), which is obtained as bottom product from ARU. H2S and other light
components present in the rich amine are separated out as overhead product.
units enter the amine flash column at a pressure of about 5 kg/cm2 and temperature of
55oC. Height of flash column is approximately 11.4 in. and dia. = 500 mm at the top and
1600 mm at the bottom of section. Top section is packed with raschig rings. Rich amine at
5 kg/cm2 is flashed into the column to a pressure of 2.8 kg/cm2. The bottom section
contains four single pass valve trays. Because of flashing, hydrocarbons in the amine get
liberated, thereby reducing the quantity of hydrocarbons going with sour gas to sulphur
The liberated hydrocarbons from the top of the column enter the flare header
through a pressure control valve. The column top pressure is maintained at 2.8 kg/cm2.
When column pressure rises, a valve opens and lets off the liberated hydrocarbons to flare
and when pressure drops pressure valve opens for fuel gas (FG) to enter the column.
47
A slipstream reflux of lean amine solution is fed into the top of column above the packing
to reabsorb any H2S liberated during flashing from the bottom of the flash column.
REGENERATION
In amine regeneration the rich DEA is stripped of its absorbed sour gases H2S and CO2
using steam. So regenerated amine can be reused in absorber. Amine reboiler is heated by
LP steam. Steam strips off the absorbed H2S and CO2 present in the DEA solution.
The top temperature of regenerator is about 105oC and middle temperature is about 115oC.
Pressure is nearly 0.5 kg/cm2. The liberated sour gases leave the regenerator from the top
and enter the overhead condenser where gases are cooled and steam is condensed to 45oC.
Sour gas from the reflux drum top goes to the sulphur recovery plant by the production of
Sulphur.
DEA overflow above the baffles to the other compartments from where it flows to
regenerator by gravity.
The excess pressure drop is due to foaming of amine inside the column. So,
A portion of cold lean amine is passed through charcoal filter to remove iron impurities
due to corrosion and to a sand filter to absorb charcoal and sent to suction line of lean
amine pump.
48
11. SULFUR RECOVERY UNIT (SRU)
11.1. INTRODUCTION
The unit consists of three identical units A, B and C. One of them is kept standby. The
process design is in accordance with common practice to recover elemental sulfur known
as the Clause process, which is further improved by Super Clause process. Each unit
consists of a thermal stage, in which H2S is partially burnt with air, followed by two
catalytic stages. A catalytic incinerator for incineration of all gases has been incorporated
process, is based upon the combustion of H2S with a ratio controlled flow of air which is
hydrocarbons and ammonia present in the sour gas feed and to burn one third of the
The major percentage of the residual H2S combines with the SO2 to form Sulphur,
49
The primary function of the waste heat boiler is to remove the major portion of heat
involved in the combustion chamber. The secondary function of waste heat boiler is to
condense the sulphur, which is drained to a sulphur pit. At this stage 60% of the sulphur
present in the sour gas feed is removed. The third function of the waste heat boiler is to
The process gas leaving the waste heat boiler still contains a considerable part of
H2S and SO2. Therefore, the essential function of the following equipment is to shift the
equilibrium by adopting a low reactor temperature thus removing the sulphur as soon as it
is formed.
Before entering the first reactor, the process gas flow is heated to an optimum temperature
by means of a line burner, with mixing chamber, in order to achieve a high conversion. In
the line burner mixing chamber the process gas is mixed with the hot flue gas obtained by
In the first reactor the reaction between the H2S and SO2 recommences until
equilibrium is reached. The effluent gas from the first reactor passes to the first sulphur
condenser where at this stage approximately 29% of the sulphur present in the sour gas
feed is condensed and drained to the sulphur pit. The total sulphur recovery after the first
reactor stage is 89% of the sulphur present in the sour gas feed. In order to achieve a figure
of 94% sulphur recovery the sour gas is subjected to one more stage. The process gas flow
is once again subjected to preheating by means of a second line burner then passed to a
second reactor and the sulphur condensed in a second condenser accomplish a total sulphur
recovery of 94%. A sulphur coalescer is installed downstream the last sulphur condenser to
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The heat released by the subsequent cooling of gas and condensation of sulphur in waste
heat boiler and, sulphur condensers results in the production of low-pressure steam.
made of vertical cylinder plates with cone roofs fixed over plates – supported by internal
truss. Depending upon the service the tanks are provided with accessories. Products like
SK, HSD, LDO and RCO are stored in fixed roof tanks.
resting on liquid contributes to the minimization of vapour space between liquid and roof
bringing are increased operational safety, and minimum evapouration loss. The floating
Foam type seal is used to seal off the clearance between the ring of the roof and
tank shell. The rim is supported, when it is not afloat, by a number of tubular legs. Each
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leg can freely move within a sleeve attached to the roof, the leg being fixed at one of the
two points by a securing pin. One fixing point corresponds to the minimum height of the
tank in the lowest working position, the other supports the roof giving sufficient clearance
between the tank roof and floor for maintenance work to be carried out. Bleeder vents in
the roof allow air to escape when an empty or near empty tank is being filled and before
volatile products in which entry of rainwater is not allowed. These tanks are used for
storing ATF, Reformer Naphtha etc. These tanks are having pan type floating roof with
drainage system. They have a fixed roof having opening to permit venting of seals in the
floating deck. These tanks are provided with inverted cone type bottom so that
Any petroleum product is ready for dispatch only after the laboratory certifies its quality.
(i) By Rail
(ii) By Pipeline
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12.2.1. PRODUCT DISPATCH BY RAIL
In Mathura Refinery following products are dispatched by railway tank wagons:
a. Motor Spirit
b. Kerosene
c. ATF
d. HSD
e. LDO
f. Furnace oil
g. Naptha
i. LPG
j. Bitumen
The facilities for loading LPG and Bitumen wagons are provided in OM&S-II area.
Different types of tank wagons are supplied by railway for different products. These are
(MJPL). In this section, the following four products are dispatched through pipeline:
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The four products are supplied to MJPL section from products storage tanks through
pumps. In this section MS/SK/HSD are filtered in one filter and ATF is filtered in another
filter. After filtration the products are pumped to the pipeline to Delhi Station and to other
LPG Section
bitumen. There are filling devices having the capacity of filling 2000 drums a day. The hot
molten bitumen at temperature of about 1050 C is filled in the drums. The capacity of each
drum is 160 kg of bitumen. The filling devices have many facilities like filling weight
indicator valve, steam supply facility. This is an automatic device. The empty drums and
filled drums are transferred to the filling device and other place in section by the roller-
conveyer. Loading the railway wagons dispatches these filled drums. The drums are kept at
yards for 48 hrs for cooling the hot bitumen. On the other, the tankers dispatch bitumen by
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13.2. LPG SECTION
Six Horton spheres each with a capacity of 750 m3 are provided for LPG storage. Of these
three spheres are for storing SR-LPG and other three are for CR-LPG storage. Inter
connections exists between all the six Horton’s spheres to maintain pressure and to enable
storage of CR-LPG in SP-LPG spheres and vice-versa. Methyl Mercaptans are mixed in
unloaded and mounted over horizontally moving conveyor belt. The belts carry the
cylinders through a set of pneumatic and steam cleaner. The cylinders are then mounted
automatically on a rotating where LPG (calculated amount per cylinder) is pumped into
cylinders. The cylinders are then immersed into the water bath to check against any kind of
leakage of LPG from the cylinders. After the normal cylinders are fitted with plastic cap
and seal the operator has to perform the job of checking the cylinders.
There are four filling points, each having a weight bridge of 30 MT capacity with dial type
seal flexible basis are connected with filling and vapour return lines. A flow meter is
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13.2.2.2. BULK LOADING BY RAIL
There are five loading points with weight bridge of 50 MT capacity each per simultaneous
loading six rail tankers each filling points per arrangement, similar to that described for
butylenes. Product has typical vapour pressure of 7-8 kg/cm2 at 38C and density 0.54-0.55
g/ml, i.e., lighter than water (0.5 times) but 0.5 to 2 times heavier than air. LPG containers
must not be completely filled with liquid and adequate vapour space must be left. As more
LPG is added to the cylinder, the liquid level raises leading to compression and
resulting in increased pressure. If there is no vapour space the liquid expands and excess
Recovery of Oil
Reduction of BOD
sulphides, etc.
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Wastewater collection system of Mathura Refinery consists of:
Industrial Sewer (IS): In this sewer, processed oily water from units, equipments,
sample points, pump house drains, electric desalter drains, loading gantries, tank
Salty Waste Water Sewer (CS): In this sewer water from crude tanks and crude
Storm Water Sewer (SS): In this, the sewer rain water from tank farm dyed area
comes.
Domestic Sewer (DS): In this, the sanitary sewage from toilets and laboratories
Caustic bearing water: Caustic bearing wastewaters from MEROX, VBU and
Physical treatment
Biological treatment
Chemical treatment
The wastewater streams emanating from different places in the refinery are different in
their characteristics and need different types of treatment. Wastewater from petroleum
refinery complex mainly emanates from process units where crude is distilled by direct
steam. Steam condenses along with petroleum products in coolers and condensers and
forms contaminated water from process unit areas. Rainwater drained from tank farms,
offside areas etc., during rainy season as well as caustic bearing wastes and blow down
from cooling towers also contributes to contaminated effluents arising from refinery. The
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pollutant characteristics of waste water from refinery are basically those of oil content,
suspended solids, spent caustic, sulfides, water soluble organics (phenol) etc.
In this treatment, physical process in AVI separators separate suspended solids and free
oils. Here the velocity of water is slowed down considerably. At such low velocities solids
settles at the bottom and free oil floats on the water surface. The oil is then skimmed off by
scrapper and sent to slop tanks. After drain of water from tank and heating to 700 C, slop
oil will be pumped to tanks in IFO, where from it will be processed in units with crude.
In the equalizer basin, at inlet, treated water from chemical treatment section also comes
and joins with water from API outlet. Here both hydraulic as well as organic loads of both
streams are absorbed and equalized. Oil skimming facility is provided here to remove free
float oil. Wastewater from here goes to single stage high rate trickling filter. Oily sludge
from oil separators will be pumped to oily lagoons. After removing supernatant, sludge
Naturally occurring bacteria eat away or oxidize impurities causing reduction of sulphides,
phenols, BOD/COD and oil using proper aerator. The excess and dead bacterium is
periodically removed from the system. Biological treatment takes place in two steps:
Trickling Filters: Water is sprayed on a stone bed using as trickle jet. Aeration is
from bottom of stone upwards due to temp difference of water and ambient air. Bacteria
grow on stone surface as film. These are washed out periodically after decaying and fresh
bacteria grow again. After the filter is put in operation, the surface of media becomes
coated with zoogles (a viscous jelly like substance) and other biots. The film of zoogles
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absorbs and utilities suspended colloidal and dissolve organic matter from waste water.
After the film grows to a limit, the liquid washes off the media and a new lime layer will
continuously mixing of waste water and activation by motor operated aerators. Here
decomposition takes place. The mixed liquor is then sent to the final clarifier where
bacteria mass is separated from water and bio-sludge is recycled. The metabolic reactions
are:
Chemical treatment is required for caustic as it has high concentration of sulphides that
cannot be removed by biological or physical treatment plant. Spent caustic from caustic
storage tank is first sent to PH tank and then it is further sent to the reactor tank where
H2O2 dose is given by using dosing pump at the rate of 60-70 lit/day. Whole reaction
mixture is sent to flocculation tank. Then floe formed out of chemical reaction is settled at
clarifier cum thickener (CCT), where from the clear water goes to equalizer basin inlet.
pumped to sludge drying beds. Chemical sludge after drying beds will be disposed off
manually.
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Equalization Ponds: Helps in supplying consistent quality and quantity of wastewater to
biological section.
Trickling filters: Helps in reducing BOD/COD, sulphides, phenols and oils in contact
Aeration tanks: Helps in further reduction of above mentioned pollutants in contact with
Slop Sumps: Receiving API, clarifier, IS and guard basin slop for pumping to slop oil
tanks.
Sludge Sumps: Receiving sludge from API Separator bottom and pumping to oily sludge
lagoon.
Polishing Ponds: provide resistance time for finishing touch with natural aeration.
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14. QUALITY CONTROL LABORATORY
Quality control is the primary function of the laboratory, assisting the Refinery’s
Production Units by providing them with quality control data on the product streams at
regular intervals. Apart from routine tests, the laboratory also handles investigation
4. ATF Laboratory.
production units, finished and intermediate products, cooling water and boiler water from
Thermal Power Station are collected at regular intervals, tested and reported to the
concerned departments through SAP. Thus this section assists the production department in
maintaining the desirable quality of the petroleum products at different stages of refining
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14.2. FINISHED PRODUCT LABORATORY
In Finished Product Laboratory, samples from finished product tanks are tested as per
specified methods and certified, if the test results meet the specifications. Some important
tests of intermediate products are also carried out in this section. CFR Research Octane
Number, Motor Octane Number and Cetane Number tests are also performed in this
Distillation of crude oil samples are also carried out in this section. It works in General
Shift.
On the basis of these test results a certificate is issued before dispatch of the material. The
laboratory is equipped with modern test equipments like JFTOT, MSEP, BOCLE etc.
monitor pollutants and to advice the remedial measures, a pollution control cell has been
set up in Mathura Refinery. In Pollution Control Laboratory, samples from ETP, Guard
Ponds, Sewage Treatment Plant, Drinking Water Treatment Plant etc are tested on regular
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basis and reported to the concerned department for remedial action, if necessary. Levels of
Air Pollution inside Refinery at different locations are also monitor regularly.
bottom of the test jar when the oil is cooled under prescribed conditions, expressed as a
multiple of 1°C.
SIGNIFICANCE
The cloud point of a petroleum product is an index of the lowest temperature of its utility
OUTLINE OF METHOD
The sample is cooled at a specified rate and examined periodically. The temperature at
which haziness is first observed at the bottom of the test jar is noted and recorded as the
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14.6.2. COLD TEST (FREEZING POINT)
This method describes a procedure for the detection of separated solids in aviation turbine
SIGNIFICANCE
It is the lowest temperature at which aviation fuels remain free of solid hydrocarbon
crystals, which may restrict the flow of fuel, if present, through filters in an aircraft fuel
system. The temperature of the fuel in the aircraft tank normally falls during flight
depending on speed, altitude and flight duration. The freezing point of the fuel must always
be lower than the minimum operational tank temperature. It is a key safety parameter in the
The sample is cooled with stirring until crystals of hydrocarbon appear. The sample is
allowed to warm up and the temperature at which the crystals disappear is noted.
cetane number using a standard single cylinder, four stroke cycle, variable compression
ratio, indirect injected diesel engine. Cetane number is a measure of the ignition
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SIGNIFICANCE
Cetane number of a diesel fuel provides a measure of the ignition quality of the fuel in
The cetane number of a diesel fuel oil is determined by comparing its combustion
characteristics in a test engine with those for blends of reference fuels of known cetane
number under standard operating conditions. This is accomplished using the bracketing
hand-wheel procedure which varies the compression ratio for the sample and each of two
14.6.4. DISTILLATION
This test is intended for the determination of distillation characteristics of crude oil and
petroleum products.
ATF, Kerosene, Naphthas, Gas Oils and similar petroleum products. The test method
and observation of temperature at the instant the first drop of condensate falls from the
lower end of the condensate tube, systematic observation of temperature against volume of
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condensate recovered at specified intervals and the maximum temperature observed during
the test are recorded. Observed thermometer readings are to be corrected to normal
Where,
The test method covers the determination the boiling range of the petroleum products at
The sample is distilled at an accurately controlled pressure between 1.0 and 50.0 mmHg.
Data are obtained from which the initial boiling point, the final boiling point and a
distillation curve relating volume percent distilled and atmospheric equivalent boiling point
SIGNIFICANCE
Atmospheric distillation provides an idea about the boiling range of the petroleum product.
characteristics of the petroleum products and fractions that may decompose if distilled at
atmospheric pressure. The boiling range is directly related to viscosity, vapour pressure,
heating value, average molecular weight and many other physical and chemical properties.
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TBP distillation provides an estimate of the yields of fractions of various boiling ranges of
a crude oil. These information are required for evaluation of a crude, designing of a
14.6.5. DUCTILITY
Ductility of bituminous material is measured as distance in centimeters to which it will
elongate before breaking, when a briquette specimen of the material are pulled apart at a
when mixed with air, forms an ignitable mixture and gives a momentary flash on
The sample is heated in a test cup at a specified rate with continuous stirring. A small test
stirring. The flash point is taken as the lowest temperature at which the application of the
test flame causes the vapour above the sample to ignite momentarily.
SIGNIFICANCE
flammability hazard of a material. Flash point and fire point have importance in connection
with legal requirements and safety precautions involved in fuel handling and storage.
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14.6.7. GAS CHROMATOGRAPHIC ANALYSIS
GC is one of the most efficient and convenient tools for separation, detection and
The sample to be tested is injected through a heated injection system and brought to vapour
form instantaneously, mixed with carrier gas and travels through the column to the
detector. The different components of the sample are separated in the column as they travel
through the column depending upon various properties of the material and the column. The
separated components are detected and subsequently quantified with a variety of detectors
like FID, TCD, ECD, FPD etc. The choice of column and detector are based upon the
SIGNIFICANCE
The technique can be used for detection and accurate estimation of components in different
MOTOR METHOD)
Octane number of the spark ignition engine fuels is volume percent of iso-octane in a blend
with n-heptane that matches the knock intensity of the fuel when compared under specified
conditions. The research octane number is determined by knock testing unit (CFR Engine)
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using the standard operating conditions given in ASTM D 2699. Whereas motor octane
number is determined using the standard operating conditions given in ASTM D 2700.
SIGNIFICANCE
Research octane number in conjunction with motor octane number defines the Antiknock
Index of Automatic Spark Ignition Engine fuels in accordance with specification ASTM D
4812. The antiknock index of a fuel approximates the road octane ratings for many
vehicles.
RON + MON
needle will penetrate vertically into a sample of the material under standard conditions of
OUTLINE OF METHOD
The sample is melted at a temperature not more than 90°C above its softening point,
poured into a container, and then air cooled under controlled conditions. The sample then
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SIGNIFICANCE
Pour point is the lowest temperature expressed as a multiple of 3°C at which the oil is
OUTLINE OF METHOD
After preliminary heating the sample is cooled at a specified rate and examined at intervals
of 3°C for flow characteristics. The lowest temperature at which movement of the sample
SIGNIFICANCE
The pour point of a petroleum product is an index of the lowest temperature of its utility
The maximum flame height in millimeters at which kerosene or other volatile liquid fuels
including aviation turbine fuels will burn without smoking, when determined in the
The sample is burned in a standard lamp in which it is possible to adjust the flame height
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raising the wick until a smoky flame is produced and then lowering to the point, where the
smoky tail just disappears. The flame height, measured to the nearest millimeter, is the
SIGNIFICANCE
The test method provides an indication of the relative smoke producing properties of
kerosene and ATF in a diffusion flame. The smoke point is related to the hydrocarbon type
composition of the fuel. A high smoke point indicates low aromatic content of the fuel.
HYDROCARBON LIQUID
This method is for the determination of vapour pressure of volatile non-viscous liquid.
The sample chamber filled with the cold sample is connected to the air chamber of the
apparatus fitted with a pressure gauge. The apparatus is then kept at a temperature of 38°C
and shaken periodically until a constant reading is obtained on the pressure gauge.
Necessary corrections are applied to this reading to get the corrected Reid Vapour Pressure
of the sample.
SIGNIFICANCE
Vapour pressure is critically important for both automotive and aviation gasolines,
affecting starting, warm up, and tendency to vapour lock with high operating temperatures
or high altitudes. Vapour pressure of crude oil is important for its safe transportation,
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REFERENCES
en.wikipedia.org
www.britannica.com
www.iocl.com
www.kbr.com
Gary, J.H. and Handwerk, G.E. (1984). Petroleum Refining Technology and Economics
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