Escolar Documentos
Profissional Documentos
Cultura Documentos
with the merger of Indian Refineries Ltd. (established 1958). IndianOil and its
subsidiaries account for 49% petroleum products market share, 40.4% refining
capacity and 69% downstream sector pipelines capacity in India.
There are ten refineries under Indian Oil Corporation Limited (IOCL)
located at
Guwahati (Assam)
Barauni (Bihar)
Baroda (Gujarat)
Haldia (W.B.)
Mathura (U.P)
Panipat (Hr.)
Koyali
Paradweep (Orissa)
Bongaigaon (Assam)
Digboi (Assam)
The combined rate capacity of these ten refineries is 49.30MMPTA.
IOC accounts for 42% of Indias total refining capa city.
HALDIA REFINERY (IOCL)
Haldia Refinery, one of the seven operating refineries of Indian Oil, was
commissioned in January 1975. It is situated 136 km downstream of Kolkata in the
district of Purba Medinipur, West Bengal, near the confluence of river Hooghly
and Haldia.
From an original crude oil processing capacity of 2.5 MMTPA, the refinery is
operating at a capacity of 5.8 MMTPA at present. Capacity of the refinery was
increased to 2.75 MMTPA through de-bottlenecking in 1989-90. Refining capacity
was further increased to 3.75 MMTPA in 1997 with the
installation/commissioning of second Crude Distillation Unit of 1.0 MMTPA
capacity. Petroleum products from this refinery are supplied mainly to eastern
India through two product pipelines as well as through barges, tank wagons and
tank trucks. Products like MS, HSD and Bitumen are exported from this refinery.
Haldia Refinery is the only coastal refinery of the corporation and the lone lube
flagship, apart from being the sole producer of Jute Batching Oil. Diesel Hydro
LPG
Naphtha
Motor Spirit ( MS )
Mineral Turpentine Oil ( MTO )
Superior Kerosene ( SK )
Aviation Turbine Fuel ( ATF )
Russian Turbine Fuel ( RTF )
High Speed Diesel ( HSD )
Jute Batching Oil ( JBO )
Furnace Oil ( FO )
ATU
LPG
SR Naph
C5 90C
90 140C
Crude
C
D
U
C
D
U
St.Run G.O
JBO
SRU
Kero Cut
CRU
Desulphurised
Fuel Gas
Sulphur
LPG
Naphtha
MS( 3 GRADES)
HGU
KHDS
MTO
RTF/ATF
H2
Kerosene
DHDS
HSD (2 GRADES)
JBO (2 GRADES)
FCCU
GO
SO
RCO
V
D
U
V
D
U
CBFS
Ext.
LO / IO / HO
FEU
SDU
NMP
DAO
HFU
S.Wax
PDA
CDWU
Asp.
70 N GR-II
150 N GR-I / II
500 N GR-I / II
850 N
150 BS GR-I/II
SR
MCW
LO
VBU
BTU
01
MCW
FO (2 GRADES)
Bitumen(3GRADES)
Bit Eml.
IFO
Fig:
OXYGEN
HEAT
Fig-02
FUEL
SAFETY:
The main & utmost thing , which is to be known to all is the safety during working
in an industry. A person in an industry should well aware about the safety rules to
keep him safe & others from any unwanted mishap.
The main principle points which one should keep in mind are:
These are the major things which one should maintain during work. But there are
many small things which should be maintained properly.
&
f. Workers should keep in mind that not to work near inflammable gases.
g. The cylinder should store in proper manner &in proper places.
These are some safety associated rule which one should keep in mind.
But these rule do not work until a person has a sense of safety.
Another main important thing is workers should know how to fight with fire.
To know this we have to know first what fire is.
In industrial language fire is nothing but a combination of heat, inflammable
material, oxygen, free radicals.
This is called fire tetrahedron. If on of the side is removed then it can be
controlled.
[Note: During fight with fire with CO2 one should always about the direction of air
flow, because one may feint if he is in wrong direction.]
O/H gasoline
o
IBP-140 C
Crude at
180-200oC
Crude oil
Pre heat
exchanger
Crude
Crude oil
Desalter
120-
95%
desalted
130 C
2nd heat
exchanger
Prefractionator
Heat
Exchanger
Crude oil
260-265oC
Pf crude
Total gasoline
IBP- 140oC
Furnace
Heavy naphtha
o
110-120 C
Kerosene/ATF
140-271oC/140-240oC
KHDS (UNIT
_23)
Kerosene
storage
Atmospheric
distillation
unit
HSD
storage
JBO
Storage
320-380oC (JBOP)
VDU
Total
S gasoline
IBPo
140 C
VB Gasoline
o
Stabilizing
column
C5-90 C boiling
hydrocarbon cuts
Gasoline
merox unit
Caustic
wash
C5-1400C
cuts
Naphtha
storage
Naptha
redistilla
-tion
column
o
Excess ( 90 Co
140 C) boiling
hydrocarbon cuts
Catalytic
reforming
unit (unit22)
90-140oC boiling
hydrocarbon cuts
Fig-04
Propane
De ethanizer
H2S+Amine
DEA Wash
mercaptan
Propane
Deasphalt unit
LPG MEROX
treatment
plant
DePropanizer
Octane
improvement
Fig-05
Caustic
butane
separation unit
LPG
storage
Motor spirit
blending
PRINCIPLE OF OPERATION:
Before feeding to the desalter, crude oil is heated to 120oC-130oC in the first set
of pre heat exchangers. In the desalter, the crude is desalted to an extent of 95%.
Crude is then heated to 260oC-265oC in the second set of heat exchangers. It is
thereafter heated to 350-360oC in furnace and thereafter fractionated in
Atmospheric Distillation Unit to the following streams having separate B.P.
ranges.
STREAMS
Total Gasoline
IBP-140
Heavy Naphtha
140-160
Kerosene/ATF
160-271
160-240
HSD
271-320
240-320
320-360
320-330
Reduced Crude
360+
385+
>400+
bottom product is amine washed for H2S removal (crudes being processed now
contain low H2S in the LPG range), hence amine washing is not required.
After amine washing, this stream is sent to Unit-13 i.e. Merox treatment plant
where mercaptan is removed. If the crude contains small amount of H2S column
12C02 is bypassed as in that case amine washing is not essential.
Reduced crude is sent to VDU i.e. vacuum distillation unit (unit-31) for further
fractionation into lube oil distillation cuts.
PROCESS DESCRIPTION
a) CRUDE OIL PUMPING : From storage crude is pumped to first set of heat
exchanger by crude feed pumps 11P02A and 11P02B before desalting . A pressure
switch to start up the spare pump is provided in case of low discharge pressure of
the running up.
b) PREHEATING OF CRUDE BEFORE DESALTER: The pumped crude is taken to
first set of heat exchanger for preheating where they get warmed by exchanging
heat with following streams:
6. Diesel drawn off: Diesel oil (gas oil) is drawn off from 19th tray in which level is
controlled by 11LC14 and is sent to the stripper 11CO2B. Lighter ends are stripped
off by steam which returns to column.
7. Heavy naphtha drawn off: Heavy naphtha is withdrawn from 35th tray . This is
sent to stripper 11CO2D under level control 11LIC01. Light ends are stripped off
by steam. H.C. vapor and steam return to the column 11C01 and H.N. (heavy
naphtha) coming from stripper bottom is pumped by 11P25A/B and ultimately
sent to HSD unit or storage.
8. JBO drawn off: From 12th tray JBO is drawn off and sent to stripper 11C02
from bottom of which JBO is pumped by 11P06A/B. heat is recovered from
exchanger 11E06 and 11E16. JBO is then sent to storage after cooling in water
cooler 11E20.
9. Reduced crude oil: Bottom of column 11C01 is stripped for removal of lighter
ends and Reduced Crude Oil (R.C.O.) is cooled by exchanging heat with crude oil
in exchanger 11E10A/B/C/D/E/F, 11E07A/B/C/D and 11E03A/B & is sent directly
as feed to VDU at the temperature of about 110OC.
PROCESS DESCRIPTION
There are three sections in this plant:
1. De-ethaniser 2. Amine wash column 3. depropaniser
(Disulphide)
Steam
Sp.gravity
Total Sulphur
Mercaptan Sulphur
( at 60OF )
( wt. % maxim)
(wt % maxim)
V.B. gasoline
0.740
1.0
0.50
S.R. gasoline
0.671
1.0
0.85
Caustic Regeneration: Caustic from merox unit is heated in a double pipe heat
exchanger and enters the oxidizer vessel where mercaptans get oxidized to
disulphides and mixture goes to disulphide separators where the disulphide oil is
separated as two layers. Regenerated caustic is sent for recirculation.
Propane Production: a part of merox treated LPG is fractionated in De-propaniser
column of gas plant to produce propane. Bottom product is send to LPG.
Splitting of C5-1400C cut: In naphtha redistillation column this portion is
fractionated into C5-90 and 90-140from overhead is routed for caustic wash to
remove H2S and then sent to naphtha storage.90-140 cut from bottom is used as
feed stock for CRU unit.
Amine regeneration: Objective of this unit is to remove H2S from H2S rich amine
received from DEA wash column from gas plant. From Amine absorber of lube
hydro finishing unit and fuel gas amine absorption unit H2S is stripped off from
amine with the help of steam. Lean amine after removal is recirculated to gas
plant, fuel gas amine absorption and LUBE HUF, stripped H2S is sent to sulphur
recovery unit for sulphur production.
THEORY OF HYDROTREATMENT:
SULPHUR COMPOUNDS: Removal of sulphur compounds is essential to avoid
poisoning of catalyst. Beside this sulphur removal helps to improve the other
quantities of gasoline like lead susceptibility, color stability, corrosion rates etc.
Different types of S-compounds e.g. mercaptans, sulfides, thiophenes etc. are also
present in crude. In operating condition and in presence of catalyst the Scompound reacts with H2 and form H2S.
REACTIONS:
R-SH (Thiol) +
H2 =
R-H + H2S
90-140 cut naphtha is taken from storage by pumping and mixed with hydrogen
make-up gas from CRU recycle compressor discharge.The mixture is then heated
in reactor where in presence of Co-Mo catalyst S, N etc are converted to H2S, NH3
and olefins get saturated and deposited on metal catalyst. Catalyst is regenerated
on furnace and reactor effluent after partly condensation during cooling, enter
the separator drum .The gas from the top is recycled by reciprocating compressor.
The liquid from the bottom is taken to stripper. Part of stripper bottom is sent to
CRU whereas the sour gas leaving the overhead is sent to fuel gas system.
PROCESS DESCRIPTION:
In CRU main categories of reactions are as follows:
Aromatization of napthenes and paraffin
Isomerisation of napthenes and paraffin
Hydro cracking of paraffin
Hydrogenation of paraffin
Olefinic hydrogenation
Other secondary reactions as demethanation, hydrosulphurisation etc.
Main types of reactions are described below.
AROMATISATION: This reaction is very fast and highly endothermic
( H = + 50 kcal/mole).In this reaction ,Octane No. increases and rate of this type
of this type of reaction increases with increasing number of C atoms.
Example: n-Hexane
Benzene
Methyl Cyclohexane
Methyl Cyclohexane + H2
KERO HYDRO
(UNIT23):
DE-SULPHURIZATION
UNIT
FEED:
The unit processes four raw kerosene distillate cuts produced from Atmospheric
Distillation Unit (ADU) of light Iranian Export Crude Oil.
1. TBP Fraction 140 271 OC
2. TBP Fraction 140 247 OC
3. TBP Fraction 140 240 OC
4. Mixture of TBP Fraction 140 271OC & TBP Fraction 170 271OC
FEED SPECIFICATIONS
Raw kerosene distillates are available from storage at the following conditions:
Temperature: 40 OC
Pressure: 1 kg/cm2 abs.
PRODUCT:
The unit can produce three different qualities of kerosene:
Superior Kerosene ( SK )
Mineral Terpentine Oil ( MTO )
Aviation Turbine Fuel ( ATF )
PROCESS DESCRIPTION:
FEED AND GAS PREHEATING SECTION
Raw kerosene feed from the storage is taken to the unit by pump 23P01A/B .The
feed is subsequently blended with a mixture of recycle and make up gases
available from discharge of the compressor 23K01A/B.Both liquid feed and gas
stream are heated in heat exchanger 23E02A/B/C/D in the shell side while the hot
reactor-effluent passes through the tube-side. Hot mixture of liquid and gas from
23E02A/B/C/D is taken to the furnace.
FURNACE AND REACTOR SECTION
Preheated kerosene and hydrogen are brought to the reaction temperature in the
furnace 23F01.The heated feed then flows across a reactor 23R01 fitted with
cobalt-molybdenum catalyst where the desulphurization reaction takes place. In
reactor there is a distributor and 39 baskets in upper part of its section. During
the catalyst regulation service air is introduced at the furnace inlet and at the
same time an adequate quantity of medium pressure steam is also introduced.
During start-up nitrogen is introduced to the reaction inlet.
EFFLUENT COOLING SECTION
The effluent from reactor is cooled and partially condensed in a series of heat
exchangers. Finally, this effluent is sent to the separator drum 23B01.
The reactor effluent is split into two phases in the separator drum 23B01.
I. The liquid phase is sent into stripper column 23C01
II. One part of vapor is sent to Hydro finishing Unit of Lube Oil block.
Another part is recycled along with makeup gas and compressed by two parallel
reciprocating compressor 23K01A/B.
STRIPPING SECTION
The liquid from the separator drum is reheated in exchanger 23E04A/B and fed
into stripper column 23C01.A part of the stripper bottom is reboiled in the heat
exchanger 23e01 on the shell side. The entire stripper bottom is pumped by
23P03, cooled and sent to storage as finished product.
The stripper overhead vapors after leaving the top of column 23C01,are first
cooled and partially condensed in the water cooler 23B02 . The liquid distillate is
returned as reflux by pump 23P02 to the top of stripper column 23C01.During
Kero/MTO run total liquid distillate is refluxed. However during ATF run, excess
liquid distillate is sent to overhead drum 11B01 of Atmospheric distillation Unit
for recovery of light distillates .There is a provision for rooting this light distillate
to storage tank.
RECOMPRESSING SECTION
The gas from reflux drum 23B02 goes via 23B02A to the first stage of the two
parallel reciprocating compressors.
The gas, after cooling on water cooler is mixed with the steam from LOB before
sending to the knockout drum 23B04. The condensed hydrocarbons from the
drum are sent to stripper column. The vapor from the knockout drum are
compressed in the second set of compressors and cooled in a water cooler. The
vapor separated liquid hydrocarbons are sent to fuel gas system or amine unit.
The condensed hydrocarbons are drained manually.
DHDS BLOCK:
RESID FLUIDISED CATALYTIC CRACKING
UNIT(unit 17/18/19):
Fluid Catalytic Cracking Unit consists of the following sections:
Fuel gas
LPG
Gasoline
TCO (Total cycle oil)
CLO (Clarified oil)
Cold feed from FCCU Feed tank and feed from process units are combined and
received to 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. Fresh feed is pumped by fresh feed pump to the feed preheat circuit.
The feed preheat circuit comprises exchangers. The fresh feed is heated in these
exchangers against HN lean oil, HCN, LCO, LCO pump around, HCO pump around
and slurry pump around. The final feed preheat is accomplished in the fire heater
before being send to the riser feed nozzles of the reactor.
REACTOR/REGENERATOR SECTION:The preheat feed is finely atomized and
mixed with dispersion steam (MP steam) in feed injectors mixing chamber and
injected into the reactor riser. Four numbers of feed injectors have been
provided. Above the feed injectors, two numbers recycle oil injectors; one recycle
slurry injector has been provided.The fine atomized feed contact hot regenerate
catalyst and vaporizes immediately. The vaporized oil mixes with the catalyst
particles and cracks into lighter, more valuable products. The heat required for
the reaction is supplied by hot regenerated catalyst. The residence time in the
riser is approximately 2.0 seconds at design conditions. Riser outlet temperature
(ROT) is regulated by controlling the flow of regenerated catalyst which is
admitted through the regenerated catalyst slide valve (RCSV).Catalyst is quickly
separated from hydrocarbon/steam vapors in the initial separator, which is
located at the end of the riser. Catalyst separation is necessary to avoid any
undesirable continuation of reaction, which produces light gases at the expense
of liquid products (gasoline and LCO).After exiting the initial separator the vapors
pass through two high efficiency single state reactor cyclones to complete the
catalyst separation from hydrocarbon products, thus minimizing the amount of
catalyst lost to product. The reactor product vapors, containing a small amount of
inert and steam, flow to the quench zone of main fractionators. Small quantities
of catalyst contained in the product vapors are carried away from the
fractionators slurry circuit.
Catalyst exiting the initial separator is pre-stripped with MP steam to reduce coke
yield. The catalyst is further stripped by steam from main stream ring as the
catalyst flows down the stripper. A series of baffles enhance the contacting the
steam and spent catalyst. The stripper used is fluidized by the stripping steam,
which displaces the volatile hydrocarbon contained on and in the catalyst
particles before they enter the first stage regenerator.
The stripped spent catalyst flows down the catalyst standpipe and through the
spent catalyst slide valve (SCSV). This valve controls the strippers levels by
regulating the flow of spent catalyst from the stripper.Spent catalyst flows to the
first stage regenerator through a distributor, which drops catalyst on the
regenerator catalyst bed. 60-70% of the coke is burnt in first stage regenerator
and remainder in second stage regenerator.
Blower driven by steam turbine supplies combustion air for combustion process in
regenerators. Atmospheric air is introduced to the air blower and discharged to
first stage regenerator risers, 2nd stage regenerator rings; lift air, withdrawal-well
ring, spent catalyst distributor sparer.
The hot regenerated catalyst flows from the second stage regenerator through a
lateral to the withdrawal well (WDW). From WDW, catalyst flows down the 45
degree slanted wyes section to the reactor riser base where catalyst begins the
upward flow toward the fresh feed injector.
First stage regenerator primary cyclones and first stage regenerator secondary
cyclones separate the entrained catalyst from the flue gas exiting the first stage
regenerator. Similarly second stage regenerator primary cyclones and second
stage regenerator secondary cyclones separate the entrained catalyst from the
flue gas exiting the second stage regenerator. Flue gas exiting both regenerators
flow to the flue gas section.
FLUE GAS SECTION:
The flue gas from the first stage regenerator passes through a double disc slide
valve, used for controlling the differential pressure between the first and second
stage regenerators. Immediately downstream of the first stage regenerator slide
valve is an orifice chamber designed to reduce the flue gas pressure.
The carbon monoxide rich flue gas exits the orifice chamber and enters to CO
Incinerator to convert the carbon monoxide to carbon dioxide to comply with
environmental emission requirements.
Hot CO Incinerator effluent combines with the second stage regenerator flue gas.
This combined flue gas passes through the Flue Gas Cooler where the flue gas
thermal energy is recovered by generating medium high-pressure superheated
steam. The cooled flue gases flow to flue gas scrubber, which further reduces the
catalyst fines and Sox in the flue gases. The off gases from the flue gas scrubber
flow to a stack..
The fractionators bottom liquid has a tendency for coking. Coking is promoted by
high temperature and long residence time. To maintain the fractionator bottoms
temperature at 360OC, a cold quench stream from the slurry pump around system
is directly mixed, under temperature control at the slurry pump section, with the
fractionator bottom liquid. Furthermore, steam is injected into the bottom liquid
to counteract coke formation and to maintain catalyst and coke particles in
suspension.In the fractionator the (Heavy Cycle Oil) HCO pump around is used to
cool further the cracked vapors from the slurry section.
Heavy cycle oil (HCO) pump around, recycle and reflux are withdrawn from a total
draw chimney tray. The reflux is pumped back to the wash tray below the HCO
chimney tray on chimney tray level control. The HCO pump around circuit is
utilised to preheat boiler feed water and to produce MHP steam in a steam
generator.The HCO recycle flows to the HCO stripper on stripper level control
where it is stripped of light components by the use of steam. Good stripping
ensures a minimum of light components, which can crack into undesirable
products once the HCO is reintroduced into the riser. The light cycle oil (LCO)
pump around and product are withdrawn from a partial draw off chimney tray.
The LCO PA is cooled down against the stripper reboiler, fresh feed, boiler feed
water, demineralised water and finally air cooler before returning to the
fractionator.The cooled net LCO product is blended with HCN to produce the TCO
product. A portion of the cooled LCO stream is used for gland and flushing oil.
Sponge absorber lean oil is drawn out of the fractionator from a partial draw off
chimney tray. The rich oil from the bottom of the absorber is then returned to the
fractionator to recover the light ends absorbed in the sponge absorber.
The total fractionator overhead vapour consists of HCN, LCN, lighter
hydrocarbons, steam and inert gases from the reactor plus the tower top reflux.
PRODUCT RECOVERY SECTION:
Two-stage centrifugal compressor compresses the wet gas from the fractionator
overhead receiver. The hot gases discharged from the first stage partially
condensed against cooling water before entering the compressor inter stage
drum.. The uncondensed vapour, the medium pressure distillate and the sour
water are separated in this drum.
The uncondensed vapours are compressed by the second stage of the
compressor. This & medium pressure distillate combined steam is then mixed
with the rich oil from the primary absorber and entering the high-pressure
separator. The uncondensed vapours are routed to the primary absorber for
C3and C4 recovery.The primary absorber recovers 95%of the propane/propylene
and 97%of the C4s from the reactor effluent. The lean oils used for absorption.
Absorption is a physical mass transfer operation characterised by its exothermic
nature, i.e. absorption of C3s into the naphtha recycle increase the temperature
of the resulting rich liquid.The unabsorbed vapors and the supplemental lean oil
are separated in the absorber reflux drum. The unabsorbed vapors are routed to
the sponge absorber.The rich oil from the bottom of the primary absorber flows
to the high-pressure separator.The sponge absorber is a tower where essentially
all of the C4s and C3s entrained in the absorber gas from the primary absorber
are recovered. The lean oil used for absorption is cooled heavy naphtha from the
fractionator. The rich sponge oil leaves the bottom of the sponge absorber is
routed back to the fractionator for recovery of the light ends (C4s and C5s). The
off gas from the sponge absorber flows to the amine unit for H2S and CO2
removal. The stripper is a tower to remove the inerts, C2s and lighter
hydrocarbons from the liquefied C3+ hydrocarbon stream to control the vapour
pressure of the recovered LPG product downstream.
The stripper overhead vapours reconnected with the wet gas compressor second
stage effluent, the compressor inter stage condensate, and the rich oil from the
absorber. The stripper bottom stream flows to the debutanizer tower. This stream
is heated and partially vapourised against debutanizer bottoms before entering
the debutanizer. The debutanizer tower produces a totally condensed overhead
mixed C3/C4 LPG product and a bottom C5+ product.The debutanizer overhead
product is totally condensed against air cooler in the overhead. LPG product is
pumped on flow control reset by reflux drum level control after being cooled
against cooling water into battery limit temperature. Exchanging heat against the
debutanizer feed cools the total debutanizer bottoms stream, comprised of the
net naphtha product and supplemental lean oil recycle. The naphtha product is
fed to the naphtha splitter supplemental lean oil recycle stream is further cooled
& combined with the absorber overhead vapors. The debutanizer bottoms
product flashes before entering the naphtha splitter tower to separate the net
naphtha product in the total feed into a light naphtha product (LCN) recovered
overhead and a heavy naphtha product (HCN) from the bottom. The light naphtha
is the overhead product. LCN product is cooled against cooling water and sent to
Merox treating unit.
2. Nitrogen removal:
Denitrogenation is generally more difficult than desulphurization. The
denitrogenation of pyridine proceeds by aromatic ring saturation hydrogenolysis,
and finally denitrogenation.
Pyridine Pyridine + 5 H2 = C-C-C-C-C (and iso-pentane) + NH3
Quinoline Quinoline + 4 H2 = Ph-C-C-C + NH3
Pyrrole Pyrrole + 4 H2 = C-C-C-C (and iso-butane) + NH3
3. Oxygen removal:
Organically combined oxygen is removed by hydrogenation of the carbonhydroxyl bond forming water and the corresponding hydrocarbon.
Phenols Phenol + H2 = Benzene + H2O
4. Olefin saturation:
Olefin saturation reaction proceeds very rapidly and has high heat of reaction.
Linear olefins C-C=C-C-C-C + H2 = C-C-C-C-C-C (and isomers)
5. Aromatic saturation:
Aromatic saturation reactions are the most difficult and are very exothermic.
Benzene + H2 = Cyclohexane
6. Metal removal:
Metals are retained on the catalyst surface by a combination of adsorption and
chemical reaction. Removal of metals normally occurs from the top of the catalyst
bed and the catalyst has a certain maximum tolerance for retaining metals.
Metals contained in the crude oil are usually nickel and vanadium. Iron is found
concentrated at the top of the catalyst beds as iron sulphides, which are corrosive
products. Sodium, calcium and magnesium are present due to the contact of the
bed with salted water or additives. Improper use of additives, to protect the
fractionators overhead systems from corrosion or to control foaming, accounts
for the presence of phosphorous and silicon. Lead may also deposit on the hydro
treating catalyst beds 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 a guard bed of catalyst specially designed for
demetallization.
7. Halide removal:
Organic halides such as chlorides and bromides are decomposed in the reactor.
The inorganic ammonium halide salts, which are produced when the reactor
effluent is cooled, are dissolved by injecting water into the reactor effluent, or
removed with the stripper off gas.
Chlorine removal Ph-C-C-C-Cl + H2
HCl + Ph-C-C-C-H
HCl + NH3
NH4Cl
PROCESS DESCRIPTION
The DHDS unit consists of the following sections:
Storage and transfer section.
Reaction section.
Compression section.
Fractionation section.
Diesel from FOB enters this unit and passes through two-filter separator of which
one (25-FS-01 A&B) is gravity separator, which separates water, and another (25FS-02) is magnetic filter separator which separates magnetic metallic particles.
The Diesel is then pumped and passed through three heat exchangers in series for
preheating. This preheated and high-pressure diesel then enters into furnace and
further heated there
Before entering the reactor, the diesel is mixed with hydrogen by means of two
compressors one is used for recycling hydrogen obtained from product stream,
and another for make-up of hydrogen which comes from the Hydrogen plant (Unit
24). It then enters two reactors in series (25-R-01 & 25-R-02). The outlet from
the second reactor is used to preheat the diesel oil in three exchangers described
above. The product from reactor i.e., diesel, hydrogen and H2S are separated in a
separator vessel (25-V-02). H2 and H2S is sent to an absorber column (25-C-01) in
which H2S is amine-washed using lean amine and the product rich amine is sent to
ARU for lean amine regeneration. Diesel and dissolved H2S are sent to stripping
column (25-C-02) with reflux in which diesel is found as bottom product. Top
product is H2S, H2O and light hydrocarbons (C1 & C2) are pumped to absorber
column (25-C-03) for amine wash. Amine washed H2S from bottom of 25-C-03 is
sent to ARU and sweet light hydrocarbon is sent to fuel gas system.
BASIC CHEMISTRY:
Hydrogen Sulphide is a weak acid and ionizes in water to form hydrogen ion and
sulphide ions:
HS + HO
H O + HS
Ethanol amines are weak bases and ionize in water to form amine ions and
hydroxyl ions:
For MEA: HO-C H-C H-N H + HO
When HS dissolves into the solution containing the amine ions, it will react to form
a weakly bonded salt of the acid and the base.
For MEA: HO-C H-C H-NH + + HS
The sulphide ion is thus absorbed by the amine solution, whose overall reaction can
be summarized as:
For MEA: HO-C H-C H-N H + HS
PROCESS DESCRIPTION:
The rich amine system receives collected amine from the amine absorbers. The rich
amine from the recycle gas scrubber and stripper gas amine absorber is fed to the
flash drum to separate any entrained liquid or gaseous hydrocarbon from the rich
amine. Hydrocarbon vapour separated, which also contains HS is scrubbed with a
small lean amine slip stream in the stack portion of the drum. Rich amine from the
bottom of the flash drum is sent through the tube side of Rich amine heat
exchanger unit where it is heated while the lean amine from the bottom of the
amine stripper is cooled. The heated rich amine flows to stripper to strip nearly all
of the HS, followed by further cooling in a Amine Stripper condenser, thus
regenerating it to lean amine.
The Sulphur Recovery Unit is designed to recover sulphur from the sour vapours
originating from the following sources.
Amine Regeneration Unit.
Sour water stripper
Unit-26
Unit-29
A knock out drum for the feed gas stream and fuel gas stream
A Claus section, consisting of a thermal stage and three reactor stages
A SUPER CLAUS stage
A thermal incinerator, burning the tail gas and vent gas of the sulphur
Degassing system
Sulphur pit with degasifying facilities and sulphur yards.
FEED CHARACTERISTICS
The feedstock of the SRU is a mixture of the "Acid gas ex ARU" and "Acid gas ex
SWS". The quality and quantity of H2S feed to the unit will vary depending on the
shutdown of the various preceding units. The unit should be capable of converting
99% wt. of the H2S contained in the feed streams to sulphur in all cases.
PRODUCT CHARCTERISTICS
The product sulphur meets the following specification after degassing :
CLAUS SECTION
The main reaction in this section takes place at main burner
H2S + 3/2 O2
The major part of the residual H2S combines with the SO2 to form sulphur,
according to the equilibrium reaction.
2 H2S + SO2
By this reaction known as the Claus reaction, sulphur is formed in the main burner
and reaction chamber.
SUPERCLAUS SECTION
In this section partial oxidation of H2S takes place according to the reaction
equation given bellow
2 H2S + O2
PROCESS DESCRIPTION:
CLAUS SECTION: By the reactions described before, sulphur is formed in vapor
phase in the main burner and combustion chamber. The primary function of
waste heat boiler is to remove the heat generated in main burner. The secondary
function of waste heat boiler is to utilize removed heat to produce MHP
stream.The process gas from the waste heat boiler is passed into the 1st sulphur
condenser, where the formed sulphur is removed from the gas.The process gas
leaving the sulphur condenser still contains a considerable concentration of H2S
and SO2. Therefore, the essential function of the following equipments is to
convert these components to sulphur.
In the 1st, 2nd and 3rd reactor stages, the H2S and SO2 again react to form sulphur
but this time at lower temperatures.
In the SUPERCLAUS stage, the remaining H2S is selectively oxidized to sulphur. For
this reason it is essential that the combustion in the main burner is such that in
the downstream of the 3rd reactor stage, the amount of H2S in the range of 0.5
0.7 volume % and the SO2 concentration is as low as possible.
Before entering the 1st reactor, the process gas flow is heated by indirect steam
to obtain the optimum temperature for a high conversion of H2S and SO2 to
elemental sulphur and simultaneously a high conversion of COS and CS2 to H2S
and SO2.The effluent gas from the 1st reactor is routed to 2nd sulphur
condenser.The process gas flow is next routed to 2nd steam reheater and then to
2nd reactor where equilibrium is established. The sulphur is condensed in the 3rd
sulphur condenser.
From the 3rd sulphur condenser, the process gas is routed to 3rd steam reheated,
and then passed to the 3rd reactor where equilibrium is established. The sulphur
is condensed in the 4th sulphur condenser.
SUPERCLAUS SECTION: The process gas from the 4th sulphur condenser is routed
to the fourth steam re-heater then passed to the reactor. Before it enters the
reactor, a controlled amount of air is added. Proper mixing is obtained in a static
mixer. In the reactor sulphur S8 is formed according to the reaction mentioned
before.
The formed sulphur is condensed in the 5th sulphur condenser. A
Sulphur coalescer is installed downstream of the last sulphur condenser to
separate entrained sulphur mist.
The sulphur condensed and separated in the condensers and coalescer is drained
via the sulphur locks and the sulphur cooler into the sulphur pits.
The tail gas leaving the coalescer still contains an amount of H2S, which is
dangerous if released directly to atmosphere. Therefore, the gas is thermally
incinerated; converting residual H2S and sulphur vapour to SO2 in presence of
oxygen. After the gas is cooled in incinerator, waste-heat boiler and super heater
it is routed to the stack. In the incinerator and waste-heat boiler, MHP steam is
produced and in the superheater MHP steam from the unit is superheated before
evaporation.
SULPHUR STRIPPING PROCESS:
The process sulphur contains H2S partially dissolved and partially present in the
form of polysulphides (H2SX). Without treatment of the sulphur, the H2S should
be slowly released during storage and transport. An explosive mixture may be
created due to exceeding the lower explosive limit of H2S in air, which may vary
from 3.7 volume % H2S at 130OC to 4.4 volume % H2S at ambient condition. The
shell sulphur degassing process has been developed to degasify liquid sulphur to
10-ppm wt H2S/H2SX that is the safe level to avoid exceeding the lower explosive
limit.
The function of this process is to enhance the decomposition of polysulfide and to
strip the H2S from the sulphur. Simultaneously, the greater part is oxidized to
sulphur. The air decreases the partial pressure of H2S and causes agitation and
circulation of the sulphur.
In this way, the H2S content is reduced from approximately from 350 to less than
10 ppm wt. The reduced H2S together with the air is routed to the thermal
incinerator, in which it is oxidized to SO2. The degassed sulphur is pumped on
level control to sulphur yard.
NAPTHA
PRODUC
T
LPG
SR NAPTHA
NAPTHA
SPLITTER
UNIT 85
NHDT
UNIT 85
LPG
NHDT &
CRU
UNIT 21 &
UNIT 22
REFOR
MATE
SPLITTE
R
UNIT 85
ISOMERIZ
ATION +
DIH + LPG
RECOVER
Y UNIT 86
I
S
O
M
E
R
A
T
E
HYDROGE
N
MS
PRODUCT
FCC
GASOLIN
E
SHU
FCC
GASOLINE
UNIT
87
SPLITTER
UNIT 87
HEAVY FCC
GASOLINE
PYROLYSIS
GASOLINE
PRIME G+
SELECTIVE
DESULPHURIZA
TION UNIT
UNIT 87
Fig: 06
Unit No.
U 31
U 32
U 33
U 34
U 35
U 36
Visbreaking Unit
U 37
U 38
U 39
U 84
FLUE GAS
SPINDLE OIL
REDUCED CRUDE
OIL
VDU
LIGHT OIL
INTERMEDIATE OIL
MP STEAM
HEAVY OIL
SHORT RESIDUE
PURPOSE:
To Vacuum Distill RCO from Crude Distillation Unit.
Vacuum Distillate is feed stock for LOBS units or FCCU.
PRODUCTS:
furnace coils. The reduced crude is then fractionated under vacuum in the column
(31C01) to obtain the following streams. A high vacuum condition and steam are
utilized to maximize the distillate recovery from reduced crude.
Streams
Gas oil
265-362
Spindle oil
362-385
Light oil
385-462
Intermediate oil
465-504
Heavy oil
504-542
Short residue
542+
Spindle oil, Intermediate oil, Heavy oil distillate and Short residue are further
processed to produce lubricating oil base stocks. Gas oil, Light oil and any surplus
distillates are processed to saleable products.
products. Some uncondensed and entrained gas oil with steam leave the top of
the column and enter the vacuum system. The gas oil and the steam are
condensed in surface condensers. The condensed oil is removed from the hot well
and separated from water in separator (31B3).
Spindle oil, Intermediate oil and Heavy oil are provided with steam stripping
facility. These products are routed to individual storage tanks. Excess quantities of
these products are routed to Fuel oil, Visbreaking Unit and to internal fuel oil
respectively. Unstripped light oil goes to either Visbreaking Unit or to fuel oil
storage tanks. Light oil can also be routed to T-761. Short residue drawn from the
bottom of the tower is sent to PDA and Visbreaking Units storage tanks. A small
quantity of hot short residue is also routed periodically to Bitumen Unit and to
TPS whenever required.
All products are cooled before sending to storage tanks by exchanging heat with
feed and water in the coolers. Short residue feed to Bitumen Unit is sent hot after
31E11 or after 31-H-1a, b.
Vacuum in the tower is maintained by a set of booster and ejectors with surface
condensers.
Operating conditions:
a) Feed inlet temperature 286 OC
b) Feed outlet temperature 400 OC
Vacuum column:
a) Flash zone pressure 100-125 mm Hg.
b) Flash zone temperature 380 OC
c) Top pressure 60-80 mm Hg.
d) Top temperature 80 OC
e) Recycle to head temperature 375 OC
f) Column base temperature 350 OC
g) Stripping stream flow rate 6780 m3/hr.
Capacity:
336.28 ton/hr
MIXIN
PROPANE
SOLVENT
STEAM
G
TANK
PROPANE
VESSEL
S
O
L
V
E
N
T
H.E.
COOLER
KO
Pot
FURNAC
E
EVAPORATION
TOWER
EXTRACTION
TOWERS
STEAM+SOLVENT
ASPHALT + LITTLE
AMOUNT OF SOLVENT
STRIPPER
STEAM+SOLVENT
EVAPORATION
TOWER
VM STEAM
STRIPPER
VM STEAM
ASPHALT (TO STORAGE)
Fig:08
This unit produces deasphalated oil (DAO) by removing asphalt from short residue
obtained from Vacuum Distillation Unit (VDU).Solvent extraction process is
chosen for removal of asphaltic material from short residue and deasphalted oil
(DAO) is recovered. Propane is used as solvent and its properties near the critical
temperature are required. Deasphalted oil is sent to Furfural Extraction Unit (FEU)
for further processing as bright stocks. Asphalt is sent as fuel to TPS and as feed
stocks to Bitumen and Visbreaking units.
PROCESS DESCRIPTION:
Extraction: The short residuum charged is mixed with propane extraction tower.
Feed enters the extraction tower and the solvent is pumped into the bottom of
the extraction tower. The heavy short residuum charge flows downwards while
the light solvent flows countercurrent upwards.
Solvent recovery: The DAO-solvent mixture flows from the top of the extraction
tower and the asphalt mixture is withdrawn from the bottom. DAO-solvent
mixture flows under pressure control from top of the tower to the solvent
evaporators 32C03 and 32C04 after getting heated through exchangers. The
major position of solvent is evaporated here. Both evaporators are maintained at
the required pressure level so that the vaporized solvent flows directly to the
solvent condenser. The remaining amount of solvent in DAO is stripped off in the
tower 32C06 by means of steam. The steam and solvent vapors pass overhead
and DAO products. The steam and solvent vapors pass overhead and DAO
products are pumped from the stripper bottom by 32P04 and level is controlled
through a stripper. Asphalt solvent mixture is taken from bottom of the tower
32C01 under level control. The mixture is heated to about 225 OC in the furnace
F1 in order to vaporize most of the solvent and to prevent foaming in the flash
tower. Vaporized solvent is separated from asphalt in flash tower C-2.
Solvent specification
Name of component
Weight %
Propane
97.5
Ethane
1.0
Butane
OPERATING VARIABLES:
By difference
Operating variables and their effects are described below. The extraction column
temperature and pressure gradient and solvent feed ratio are the most important
among them.
1. Extraction temperature and temperature gradient: Above 38 OC propane has a
negative temperature co-efficient in respect of asphalt and resin solubility. The
top and bottom temperature are maintained at 68 OC and 52 OC respectively.
These temperatures are raised depending on the feedstock and product quality
that are desired. Increasing the top temperature will precipitate and further
quantity of asphalts of gradually lower molecular weight. Feed temperature
affects the top temperature to some extent. The bottom temperature is
maintained constant by maintaining the solvent entry temperature for a steady
degree of extraction.
2. Temperature of the evaporator and stripper: Top and bottom temperature are
maintained in such a way that all propane and steam escape from overhead but
no oil vapor should go with them.
3. Extraction tower pressure: Higher the pressure sharper the separation.
Pressure is maintained at 40 kg/cm2, so that the solvent will remain in the liquid in
the operating temperature.
4. Evaporator stripper pressure: Proper pressure gradient is maintained between
C-3 and C-4 so that the liquid flow can be smooth. The pressure in the evaporator
column will depend upon the pressure in propane condenser E-6. The pressure in
the stripper and condenser should be sufficiently low for maximum solvent
recovery.
5. Solvent feed ratio: Solubility of asphalt and resins in lower paraffinic
hydrocarbons increases in the order C-4, C-3 , C-2 . Solvent composition is
maintained for steady product quality.
TO ATMOSPHERE
RAFFINATE
FEED
STOCK
DE-AERATOR
FURFURAL
VM
STEAM
EXTRACTOR
Fig:09
FURFURAL
EXTRACTION UNIT
(UNIT- 33)
EXTRACT
QUALITY MONITORING:
Raffinate: KV @ 100oC, RI, CCR.
Extract: Density.
The Furfural extraction unit includes the following sections:
1. De aeration
2. Furfural extraction
3. Raffinate separation
4. Extract separation
5. Solvent recovery
From raffinate solution From extract solution
From water-furfural & furfural-water mixture
PROCESS DESCRIPTION:
1. De aeration section: Distillate oil is taken from the storage tanks and pumped
using 33-P1-1/1R through heat exchangers 33-E-1A/B ( distillate oil vs. de aerator
bottom ) and then through feed-steam heat exchangers 33-E-2A/B ( distillate oil
vs. extract rundown or extract recycle ) and thereafter enters the de aerator
column 33-C-1 . An absolute pressure of about 150 mm Hg. is maintained in 33-C1 using ejector or condenser.
2. Furfural extraction section: De aerated distillate oil is pumped through a
charge cooler and then enters the extractor in which two phases are formed. The
raffinate with low content of furfural is discharged at the extractor top and the
extractor is discharged at the bottom.
3. Raffinate separation: The raffinate enters a vessel 33-B-1 provided with an
inert gas blanket from where it is pumped through heat exchangers and heated
in furnace 33-F-1 from where it is discharged at 220 OC .
4. Extraction separation section: From the extractor the extract is pumped
through a series of heat exchangers, temperature rising to 91 OC. A part of the
furfural section is eliminated in the bottom portion of the extract pressure flash
tower and the rest is heated to 230 OC in the extract furnace and then enters the
extract pressure flash tower at the top .
5. Solvent recovery from raffinate solution : The solution at 220 OC enters the
raffinate flash tower at 150 mm Hg. Furfural vapors discharged overhead at 114OC
enters the cooler operating at 100 mm Hg from, where liquid furfural is pumped
at 60 OC is pumped into the extractor .Temperature at the top of the raffinate
flash tower is maintained by furfural reflux. The raffinate solution from the
bottom of the raffinate flash tower is steam stripped. Furfural vapor and water
vapor and water vapor discharged from the top at 70 OC pass through a cooler at
60 OC and then through a cooler at 60 OC and then through a vessel provided with
an inert gas blanket.
6. Solvent recovery from extract solution: This is done in two stages:
a. Furfural vapor from the extract pressure flash tower at 180 OC are cooled in
drying solvent tower to 165OC. The furfural vapors discharged from the top of the
extract pressure flash tower (operates at 2-7 kg/cm2) enters the drying solvent
tower via heat exchanger.
b. From the bottom of the extract pressure flash tower the extract solution
containing a low quantity of furfural passes into extract vacuum flash tower at
150 mm Hg. from where furfural vapor is at 114 OC and passes into cooler . The
extract still contains furfural and is steam stripped. From the bottom of the
extract vacuum flash tower, furfural is pumped from the extract at 168-192 OC to
steam generator from where it goes to storage tanks.
7. Neutralization with sodium carbonate solution: To prevent corrosion sodium
carbonate solution is injected into following circuit:
Water vapor and furfural vapor
Furfural vapor and water vapor
Quality Monitoring:
DWO: Pour point, Flash point, KV @ 100oC & 40oC
Slack Wax: Flash Point.
Objective:
To remove paraffinic hydrocarbons to remove paraffinic hydrocarbons from the
extract to the low pour point to make it suitable for low temperature application.
PROCESS:
Extraction and crystallization to achieve dewaxing with the addition of SDA
followed by filtration and solvent recovery.
SECONDARY
DILUTION SOLVENT
FEED STOCK
TRAIN OF DP
CHILLERS
SDA DOSING
(PRIMARY
DILUTION
SOLVENT)
ROTARY
VACUU
M
FILTER
WAX TO FCCU
SOLVENT +
DWO
STRIPPER
SOLVENT
DRYING
TOWER
VM STEAM
SOLVENT RECOVERY
SECTION
Fig:10
Solvent:
MEK & Toluene in equal proportions. Toluene is oil solvent & MEK is antiwax solvent.
Antiwax Solvent:
Antiwax solvent, also called wax-rejecter (MEK) is used to avoid solubility of wax
in oil solvent i.e., toluene. MEK is useful in this purpose for its poor oil miscibility
character. Toluene and MEK should be blended in such a way so that it impose
highest solvent effect on oil and little solvent effect on wax.
Crystallization:This process takes place with nucleation and growth. It is a very
complex process in which both mass and heat transfer takes place in a
multicomponent system like wax.
PROCESS DESCRIPTION:
The unit is subdivided into the following sections:
Feed solvent recovery section: The molten waxy feed is mixed after primary
dilution in various proportions depending on the grade and viscosity of lube
raffinate. The solution is first heated in a steam heater to homogenize the feed
mixture 5-10oC above its cloud point. The solution is cooled under controlled
condition first in water cooler to the nucleation temperature then in a tank of
scrapped surface exchangers and chillers employing cold filtrate and liquid
ammonia as cooling medium respectively.
Ammonia chilling section: Feed mixture stream before joining from two feed
streams into one are cooled to a temperature just above the cloud point to
ensure that crystallization will start only in DP exchangers. The feed mixture is
then distributed into seven parallel trains with each train comprising of two
double pipe scrapped surface exchanger (LR) followed by three DP chillers (LR) in
series. The secondary dilution is added at set temperature to each train at the out
first DP chiller or at the first DP chiller. The exact location of secondary of solvent
injection point can be varied and is chosen for different feed stocks as required.
Filtration section: The feed mixture stream after further chilling in third DP chiller
of each train are joined and are routed to the filter feed drum. The territory
dilution solvent is added before it goes to filter feed drum. The solvent train is
joint to both streams and used where it is necessary. The chilled feed mixture in
the form slurry of wax crystal in oil and solvent flows by gravity from filter feed
drum which is blanked with inert gas and is distributed to ten parallel filtration
trains. The filter drum carrying filter media is submerged and rotates in the filter
vat filled with the chilled slurry of dewaxed oil solvent mixture containing
suspended wax crystal. Inert gas vacuum compressor produces the vacuum. As
the wax cake is formed on the filter cloth the cold solvent at the filtering
temperature washes it continuously. After the cold washed zone, the inert gas is
drawn through the filter cloth in order to dry the cake. Blowing the chilled inert
gas from inside the filter cloth then dislodges the washed cake. A doctor blade is
gently removed the cake over to a rotating scroll conveys it to the filter boot (34B-3). A steam coil in the filter boot heats up the wax mixture. The wax mixture is
pumped by filter boot pumps to slack wax solvent recovery section. The dewaxed
oil (DWO) mixed filtrate and the inert gas from filtrate receiver flows to inert gas
drum to eliminate any entrainment before it enters to the inert vacuum
compressor.
Solvent recovery section: The DWO mixture is heated and vaporized by the
overhead vapor from the DWO first flash column (34-C-1) and DWO second flash
column (34-C-2) by 34-E-5 A/B and 34-E-7 A/B/C/D exchangers. The bottom liquid
is fed to second flash column (34-C-2). The overhead solvent of 34-C-3 vapors go
for solvent drying (34-C-10) where bottom liquid of 34-C-3 flows by gravity to 18th
tray of DWO stripper (34-C-4). In DWO stripper superheated low pressure stream
is introduced at the bottom to remove the remaining solvent from the DWO. The
product DWO from 34-C-4 column, bottom is routed to storage.
Refrigeration section: The refrigeration section consists of three basic cycles
compression, liquefaction and evaporation. It is a closed circuit system. Ammonia
vapors rescued from the cooler, chiller, heat exchangers are send to the
refrigeration section for the two cooling stages at 15oC and 30oC respectively.
The plant is equipped with two centrifugal compressors for compression of such
vapor.
AMINE SOLVENT
DWO OIL
FEED
OFF GAS
FURNACE
HYDROGEN GAS
COMPRE
SSOR
AMINE
ABSORBER
CATALYTIC
REACTOR
SEPARATOR
R
I
C
H
OFF GAS
A
M
I
N
E
E
H2 GAS
STRIPPING
COLUMN
K.O. DRUM
STRIPPING
COLUMN
SOUR WATER
DRAIN
REGENERATED AMINE
STRIPPING STEAM
PRODUCT
Fig:11
PROCESS DESCRIPTION:
The following chemical reactions are involved:
Desulphurization: The sulfur is present in the feed under various forms such as
mercaptans, sulphides, disulphide and combined form in cycles with aromatic
character (thiophenic sulphur).The decomposition of sulphur compounds are
illustrated here after:
Mercaptans
RHS + H2 = RH + H2S
Sulphides RSR' + 2 H2 = RH + R'H + H2S
All these reactions produce H2S consuming H2 and are exothermic. In
hydrofinishing required reactions are mainly the desulphurization of sulphides,
disulphides, mercaptans and partly of some sulphur combined form in such a way
that some aromatic compounds with sulphur remain in the lubes. These
compounds act as antioxidants and allow additive economy.
Mild hydro-denitrification: Nitrogen is contained essentially in heterocyclic
compounds. When hydro finishing raffinates, a large part of undesired nitrogen
compounds are removed at previous treatment which is solvent extraction.
Nevertheless, for some typical highly nitrified crude some hydro-denitrification is
required in hydrofinishing for reaching better cooler stability.
Amines RNH2 + H2 = RH + NH3
The ultimate products of hydro-denitrification are hydrocarbons and ammonia.
Hydrogenation of olefins: Some olefins can be present in the raffinates but
generally in low quantity. Most of them are saturated during hydrofinishing
reactions. The corresponding measurement is the Bromine Number Value.
liberation of some aromatic rings towards the light compounds which are stripped
to reach the required flash point.
Decomposition of oxygenated compounds and other reactions: Generally, the
oxygenated compounds are mostly removed at the solvent extraction step. If still
any, they will be removed with hydrofinishing.
The unit can be divided into two distinct sections viz.
1. Reaction section.
2. Stripping section.
In the first section the reactions mentioned above is effected under controlled
conditions while the second section describes the removal of the reactants, gas,
etc. from the finished Lube Base Stocks.
Flue gas
feed
Heat
Bitumen
Air
Steam
Water
Fig:12
OPERATING VARIABLES:
1. Column Temperature
2. Air blowing rate
3. Residence time
VISBREAKER NAPTHA
GAS OIL QUENCH
GAS OIL
FEED
FURNACE
FRACTIONATOR
VB TAR (FOR FURTHER
PROCESSING)
SOAKER
VISBREAKER
Fig:13
Gas, gasoline and visbroken tar are the products of this process. Amine
regeneration unit, Kero-HDS unit and hydrofinishing unit are all burned in the
flare which was the main problem for decreasing air pollution so the installation
of this unit became necessary. All the H2S from the units are recovered as
elemental sulphur (about 99.9%). The design intention of SRU is to recover
sulphur from the feed and to allow a maximum of 10 ppm of H2S in the final flue
gas going to the stack.
KNOCK OUT
POT
CBD
FEED
DE-AERATOR
SOLVENT
NMP
RAFFINATE
(12-20% SOLVENT)
STEAM
EXTRACTOR
EXTRACT
(78-83% SOLVENT)
TO VACUUM
CONDENSATE
DRUM
VACUUM FLASH
COLUMN
TO SOLVENT
DRYER
EXTRACT
STRIPPER
STEAM
Fig:14
EXTRACT R/D
PROCESS DESCRIPTION:
The unit typically consists of the following section:
1. De aeration/extraction section: Objective of this section is to remove dissolved
air in feed. Though NMP is thermally stable, dissolved air will accelerate its
degradation. This is done in 38C01 through stripping steam.Objective of the
extraction system is to extract out condensed aromatics and polar compounds
from feed, to improve color, VI, flow characteristics of feed stock. This is done in
38C02, which is a 7 bed packed tower.
2. Raffinate recovery section: it separates raffinate from raffinate mix by vacuum
flashing and steam stripping after heating in a raffinate mix furnace.
3. Extract recovery section: it separates solvent and extract from extract mix by
carrying out flashing at different temperatures and pressures and finally stripping
with steam at pressure below atmospheric.
4. Solvent drying section: to remove water coming along with solvent recovered
at different recovery stages to a desired level of water in the solvent to be used as
solvent in the solvent extraction column and as reflux in various section.
5. Solvent utility/conservation section.
FEED: 100N/ 150N/ 500N/ 150 BS & 500N raff & SL wax mixture & 500N slack
wax.
THE PROCESS:
In this unit there are three reactors HDT, MSDW, HDF. In HDT the waxy feed is
hydro treated in order to remove impurities like sulphur, nitrogen, oxygen which
poisons the catalyst. In MSDW (Mobile selective dewaxing) the wax is removed in
presence of catalyst. In HDF the product is hydro finished to improve its quality.
PROCESS DESCRIPTION:
Feed section: Waxy oil is first heat exchanged in heat exchangers 84-E-01.it is
then filtered in oil feed filter. The feed is then passed to feed coalescer from
where after coalescing it goes to oil feed surge drum 84-B-01.
Preheat Section: Feed is preheated in heat exchanger 84-E-02 with HDF reactor
effluent. The recycle gas is added to it. It is again preheated in heat exchanger 84E-03.Preheated feed is then heated in HDT reactor charge heater. 84-F-01.
Reaction and product separation: Heated feed goes to HDT reactor 84-R-01
where hydro treating reaction takes place where nitrogen is converted to NH3
while sulphur to H2S.Reaction is exothermic in nature, so interbred quenching is
done to maintain reaction temperature. The reactor effluents are cooled in
feed/HDT effluent heat exchanger 84-E-03. To maintain feed temperature to
stripper some portion is bypassed. This partially cooled effluent is sent to HDT
effluent stripper 84-C-01 where phase separation takes place.H2S and NH3 are
stripped from resulting liquid phase using hydrogen make up gas. Column bottom
liquid is routed to MSDW feed /effluent heat exchanger 84-E-06.A part of the
liquid may b routed to raffinate stabilizer for stabilization. Vapor from stripper 84C-01 is cooled in HDT stripper overhead/feed gas heat exchanger 84-E-04 and
then air cooled in 84-EA-01while further cooling is done in train cooler84-E-05.
Low pressure recovery section: The liquids are stripped for the separation of
naphtha and lighter material from the de waxed oil stream. The vapors are
condensed and contacted with lean amine in the low pressure amine absorber,
for H2S removal, before discharge into the fuel gas header. The bottom products
are sent to the vacuum fractionators, where distillate and lighter material is
separated from the de waxed oil. The vapors are sent back to the furnace firebox.
The de waxed products are vacuum dried and cooled.
OPERATIONS:
Crude oil received from tankers and after proper setting and draining is fed to the
crude distillation unit. Intermediate products are received either by finished or
semi-finished condition. Semi-finished products are converted to finished
products either by blending or by further processing in other unit. Rail, road,
sea/river, and pipelines as per plan then dispatch them.
Tank Farm
Bitumen filling station
Tanker truck loading
LPG storage
Effluent treatment plant
TANK FARM:
Types of tanks:
Generally, the tanks used for storing petroleum products are:
i) Fixed cone roof type
Generally, the tanks are calibrated as per ISI standard. Tanks are calibrated by
CPWD Engineers.
The measurement of petroleum involves three operations
i) Gauging the tanks
ii) Recording the temperature of the product
iii) Drawing a representative sample of the product
A special machine called Fork lift is used which can move 3-4 drum form the
loading station to the field where it is stored.
The loading is controlled by several sensors which enable the empty drum to be
placed at the proper level below the discharge pipe, proper positioning of the
empty drum on the conveyor at the proper level below the discharge pipe and the
exact amount of bitumen to be filled into each tank.
A total of 18,000 MT/a of bitumen are produced in Haldia Refinery.
Products
The loading is done mainly through automation. Some parts are done manually
when required. The instrument used is MERCURY METER and PD METER
(volumetric flow meter). The capacity of tank filled here are within 3000-6000 lt.
UNIT NUMBER
QUANTITY(m3/hr)
11
8-16
16
5-12
FLUIDISED CATALYTIC
CRACKING UNIT
MOTOR SPEED QUALITY
CONTROL
18
28-32
86
1.5-3
A very small quantity is also produced from Hydro cracker Unit (HDCU)-unit91.
TYPES OF LPG:
TYPES
FACTORS
PROPERTIES
STRAIGHT RUN
High octane number.
CRACKED
Comparatively low
USES
octane number.
Higher calorific value.
For domestic use &
commercial purposes.
STORAGE UNITS:
UNITS
BULLET
150
HORTON SPHERE
1500
MOUNDED BULLET
1500
Bullets
Bullets are long cylindrical shaped storage vessels. They are somewhat like
pressure vessel, and maintain vapour liquid equilibrium inside it.
Horton Spheres
These are large spheres of 1500 m3 capacity used in Haldia Refinery of IOCL for
storage of LPG.
The significance of the design of Horton spheres are:
(i)
The spherical shape ensures less vapour formation since least area is
provided, for same volume of liquid LPG, as compared with the other shapes
of containers. Thus minimizing pressure build up inside the spheres and
reducing chances of enormous explosions.
Mounded Bullets
Mounded Bullet storage comprises a cylindrical shaped vessel surrounded by
stones, sand, etc. to absorb the impact of any accidental explosion. It also does
not have the problem of support as there was in Horton spheres. With 59m
length, 6m diameter and 1500m3 capacity of the cylindrical vessel, Haldia refinery
of IOCL has 3 such mounded bullets. Its design pressure is about (14.5kg/cm2) (g).
They are also subjected to cathodic protection to restrict rusting of the vessel
body.
DOMESTIC SEWRAGE:
All the sanitary from toilets and the canteens provided in the refinery (including
the administrative building) are connected to this system. This connection is made
partly by gravity and partly by pumping.
c) Suspended solids:
These are the sand particles, silt, algae and some iron compounds. Effects of
these suspended solids are: water becomes turbid, diminishes the sunlight
penetration and thus reduces the photosynthesis and the replenishment of
oxygen, deposition at the bottom affects the water bottom life.
d)Furfural:
The furfural is used in used in the FEU as solvent which at times it finds its way to
water sewers. Its effects are: due to presence of this BOD/COD values will be high,
the reduction of phenols, sulphides, oil in treatment plant becomes poor.
2) BIO-CHEMICAL OXYGEN DEMAND (BOD):
It is not a pollutant itself, but its a characteristic of water which in turn depends
on other pollutant. The organism like bacteria and all other things in water utilizes
dissolved oxygen in water for their respiration and multiplication. Thus there is
loss of oxygen in water and this loss is normally made up by rearetion from
atmosphere by using the aerobic bacteria. The water having pollutants will have
high BOD value. Thus BOD is defined as the amount of oxygen expressed in
milligrams per litre required to oxidize components of waste water biologically.
Effects of high BOD value are:
i) Survival of water bodies is endangered.
ii) The water bodies become anaerobic and give rise to smell.
iii) Water bodies become unfit for beneficial use
3) CHEMICAL OXYGEN DEMAND (COD):
The chemical oxygen demand (COD) test is commonly used to indirectly measure
the amount of organic compounds in water. Most applications of COD determine
the amount of organic pollutants found in surface water (e.g. lakes and rivers),
making COD a useful measure of water quality. It is expressed in milligrams per
litre (mg/L), which indicates the mass of oxygen consumed per litre of solution.
Older references may express the units as parts per million (ppm).
The difference between BOD & COD is only the testing method. In case of BOD
testing, the oxygen requirements are determined by the use of bacteria & it takes
5 days for testing. However in case COD, the test method utilizes chemicals and
hence can be completed in three hours. All impurities oxidized in the COD test
may not be consumable by bacteria and COD values are always higher than BOD
values.
operations. In Haldia Refinery, bar screen, wire mesh, and API Separator (in case
of modernized installation Tilted Plate interceptor) are used for purpose of
physical treatment. Effluent is first admitted through bar screen and then wire
mesh where debris, rags etc. are removed & then sent through grid chamber to
settle out suspended solids. The purpose of these two equipments is to protect
the downstream mechanical equipment and avoid deposition in sumps and
channels. The waste water with free oil and sludge is then routed through the API
separators and then the primary sedimentation equipment. Here the velocity of
the influent is slowed down considerably, at such a low velocity, the suspended
particles of higher density are made to settle down and the oil of low density
floats. In API around 50% to 60% of suspended solids are removed and 20% to
40% of the BOD at 20oC is achieved.
b) Chemical Treatment:
Chemical treatment followed by physical treatment reduces colloidal solids,
inorganic chemicals, some portion of organic chemicals and the remaining
suspending solids of the effluent.
Important unit operations and processes which are used for this purpose are:
i) Chemical coagulation, flocculation and sedimentation
ii) Filtration
iii) Ion exchange
iv) Reverse osmosis
v) Carbon adsorption
In Haldia refinery method number (i) along with oxidation of chemical both
organic and inorganic (especially sulphide and phenolic compound) by chlorine is
followed. Coagulation is the process in which chemical which is termed as
coagulant are added to an aqueous system to create rapidly settling aggregate
out of present. Flocculation is the second stage in the formation of this aggregate
which is achieved by gentle and prolonged mixing. Over here coagulation occurs
in pre-aeration chamber.
[the coagulant] solution and lime solution are
added in pre-aeration chamber. Positively charged iron ions neutralize the
negative charges of emulsified oil and hence releases the oil from water. These
iron ions are hydrolyzed by hydroxides [like
] to form
flocs.
Dissolved
in the effluent oxidizes the
to
flocs which
settles at faster rate than
. For highest efficiency a rapid and intimate
mixing of
/
flocs with effluent is necessary before flocculation
process begins, which is done in flash mixer chamber where a motor driven stirrer
is rotating continuously.
Flocs so formed are too light to settle under gravity, thus from the flash mixer
chamber the effluent goes to clariflocculator where slow stirring is done by two
continuously rotating motor driven stirrer thus enabling flocculation i.e.
agglomeration of small flocs. Entrainment and absorption of suspended particles
(such as free oils, Fes etc.) occurs on the large surface area of the agglomerated
/
flocs which settle down at the clarifier zone of the
clariflocculator.
c) Biological Treatment:
After physical and chemical treatment waste water is to biological treatment
under aerobic condition (i.e. a condition denoting an excess of free dissolved
oxygen (o2) in biological system) for further reduction of organic pollutant. The
principles involved are to utilize naturally occurring bacteria to eat away or
oxidize organic impurities there by reducing the concentration of pollutants.
These bacteria simultaneously get biodegraded. The excess of bacteria is removed
from the system periodically. The basic biochemical reaction for the stabilization
of organic impurities under aerobic condition by micro-organisms in waste water
isOrganic
as follows:
impurities + microbes + O2
A more microbes +CO2 +H2O +waste energy
The common systems for biological treatment are Trickling filter and Activated
sludge tank also called as aeration tank or bio-reactor. Both are used in Haldia
refinery.
In case of trickling filter (bio filter) system, waste water is sprayed on bed of
stones. The aeration is form on the bottom of the stones upwards, due to
temperature difference of water and the ambient air, bacteria grows on the stone
surface as a film which eats away organic impurities. These bacteria decay and
wash out periodically. Fresh bacteria grow again on the stones.
In case of activated sludge tank, the bacteria are continuously mixed with waste
water and aerated by motor operated aerators. Here also bacteria eat away
impurities. The bacteria water (mixed liquor) is then sent to clarifier from aeration
tank where bacteria mass separated from water. The bacteria mass is recycled
back to aeration tank to maintain required level of bacteria in aeration tank.
Fig: 15
The balance of bacteria is sent to biological sludge lagoons (this operation is done
periodically) for disposal. The water from clarifier goes to treated water pond,
ready for disposal to river.
The nutrient used in Bio-reactor is Urea.
CENTRIFUGAL PUMPS:
CENTRIFUGAL PUMP
Fig: 16
RECIPROCATING PUMP
Fig: 17
GEAR PUMP
Fig: 18
SCREW PUMP:
SCREW PUMP
Fig: 19
Screw pumps are rotary, positive displacement pumps that can have one or more
screws to transfer high or low viscosity fluids along an axis. A classic example of
screw pumps is the Archimedes screw pump that is still used in irrigation and
agricultural applications.
Although progressive cavity pumps can be referred to as a single screw pumps,
typically screw pumps have two or more intermeshing screws rotating axially
clockwise or counterclockwise. Each screw thread is matched to carry a specific
volume of fluid. Like gear pumps, screw pumps may include a stationary screw
with a rotating screw or screws. Fluid is transferred through successive contact
between the housing and the screw flights from one thread to the next.
Geometries can vary. Screw pumps provide a specific volume with each cycle and
can be dependable in metering applications.
It is used mainly in water and water treatment applications.
VALVES:
Valves are devices which regulate flow of fluids (gases, liquids, fluidized solids, or
slurries) by opening, closing, or partially obstructing various passageways. Valves
are technically pipe fittings, but are usually discussed as a separate category. In an
open valve, fluid flows in a direction from higher pressure to lower pressure.
Valves used in the plants can be categorized into:
Butterfly valve
Check valve
Control valve
Gate valve
Globe valve
BUTTERFLY VALVE:
A butterfly valve is a valve which can be used for isolating or regulating flow. The
closing mechanism takes the form of a disk. Operation is similar to that of a ball
valve, which allows for quick shut off. Butterfly valves are generally favored
because they are lower in cost to other valve designs as well as being lighter in
weight, meaning less support is required. The disc is positioned in the center of
the pipe, passing through the disc is a rod connected to an actuator on the
outside of the valve. Rotating the actuator turns the disc either parallel or
perpendicular to the flow. Unlike a ball valve, the disc is always present within the
flow; therefore a pressure drop is always induced in the flow, regardless of valve
position.
BUTTERFLY VALVE
Fig: 20
CHECK VALVE:
A check valve, a valve which normally allows fluid (liquid or gas) to flow through
it in only one direction.
Check valves are two-port valves, meaning they have two openings in the body,
one for fluid to enter and the other for fluid to leave. There are various types of
check valves used in a wide variety of applications. Check valves are often part of
common household items. Although they are available in a wide range of sizes
and costs, check valves generally are very small, simple, and/or inexpensive.
Check valves work automatically and most are not controlled by a person or any
external control; accordingly, most do not have any valve handle or stem. The
bodies (external shells) of most check valves are made of plastic or metal.
CHECK VALVE
Fig: 21
CONTROL VALVE:
Control valves are valves used to control conditions such as flow, pressure,
temperature, and liquid level by fully or partially opening or closing in response to
signals received from controllers that compare a "setpoint" to a "process
variable" whose value is provided by sensors that monitor changes in such
conditions.
CONTROL VALVE
Fig: 22
GATE VALVE:
A gate valve, also known as a sluice valve, is a valve that opens by lifting a round
or rectangular gate/wedge out of the path of the fluid. The distinct feature of a
gate valve is the sealing surfaces between the gate and seats are planar, so gate
valves are often used when a straight-line flow of fluid and minimum restriction is
desired. The gate faces can form a wedge shape or they can be parallel. Typical
gate valves should never be used for regulating flow, unless they are specifically
designed for that purpose. On opening the gate valve, the flow path is enlarged in
a highly nonlinear manner with respect to percent of opening. This means that
flow rate does not change evenly with stem travel. Also, a partially open gate disk
tends to vibrate from the fluid flow. Most of the flow change occurs near shutoff
with a relatively high fluid velocity causing disk and seat wear and eventual
leakage if used to regulate flow.
GATE VALVE
Fig: 23
Typical gate valves are designed to be fully opened or closed. When fully open,
the typical gate valve has no obstruction in the flow path, resulting in very low
friction loss.
Gate valves are characterized as having either a rising or a no rising stem. Rising
stems provide a visual indication of valve position because the stem is attached to
the gate such that the gate and stem rise and lower together as the valve is
operated. No rising stem valves may have a pointer threaded onto the upper end
of the stem to indicate valve position, since the gate travels up or down the stem
on the threads without raising or lowering the stem.
GLOBE VALVE:
A globe valve is a type of valve used for regulating flow in a pipeline, consisting of
a movable disk-type element and a stationary ring seat in a generally spherical
body.
GLOBE VALVE
Fig: 24
Globe valves are named for their spherical body shape with the two halves of the
body being separated by an internal baffle. This has an opening that forms a seat
onto which a movable plug can be screwed in to close (or shut) the valve. The
plug is also called a disc or disk. In globe valves, the plug is connected to a stem
which is operated by screw action in manual valves. Typically, automated valves
use sliding stems. Automated globe valves have a smooth stem rather than
threaded and are opened and closed by an actuator assembly. When a globe
valve is manually operated, the stem is turned by a hand wheel.
Globe valves are used for applications requiring throttling and frequent operation.
FURNACE:
Furnaces are used in the plant mainly for heating the fuel oil, heating of air. A
many number of furnaces are used in the plant. Some furnaces are side by side or
divided by walls.
DAMPER
AIR PREHEATING
SECTION
AIR TO FD
ID FAN
CONVECTION ZONE
FO
FEED IN
STEAM
RADIATION ZONE
AIR
FURNACE
VALVES
FEED OUT
BURNER
DUCK
FD FAN
FURNACE WORKING LAYOUT
Fig: 25
In furnace first the air is preheated; as the temperature of air has to be increased
for lesser consumption of fuel. The air required for burning is obtained via use of
Force draft fan.
Damper is used in the chimney which controls the flow of flue gas.
Steam and fuel oil is passed which is used for heating the oil and air.
The flue gas generated is hot air so the heat of it is utilized for preheating of air.
This is done by the use of Induced draft fan as shown in the figure.
In the furnace the heating is done in two zones;
Convection zone
Radiation zone
The crude or feed is first heated in convection zone where the heating first takes
place through convection heat transfer from hot air to the oil.
Then the final heating is done in the radiation zone where the maximum heating
is done as in this mode the heat transfer is maximum.
Various valves are used which controls the flow of the fuel oil and the steam.
HEAT EXCHANGERS:
A heat exchanger is a device built for efficient heat transfer from one medium to
another. The media may be separated by a solid wall, so that they never mix, or
they may be in direct contact. They are widely used in space heating,
refrigeration, air conditioning, power plants, chemical plants, petrochemical
plants, petroleum refineries, natural gas processing, and sewage treatment.
In company mainly shell and tube heat exchangers are used.
Two fluids, of different starting temperatures, flow through the heat exchanger.
One flows through the tubes (the tube side) and the other flows outside the tubes
but inside the shell (the shell side). Heat is transferred from one fluid to the other
through the tube walls, either from tube side to shell side or vice versa. The fluids
can be either liquids or gases on either the shell or the tube side. In order to
transfer heat efficiently, a large heat transfer area should be used, leading to the
use of many tubes. In this way, waste heat can be put to use. This is an efficient
way to conserve energy.
Heat exchangers with only one phase (liquid or gas) on each side can be called
one-phase or single-phase heat exchangers. Two-phase heat exchangers can be
used to heat a liquid to boil it into a gas (vapor), sometimes called boilers, or cool
a vapor to condense it into a liquid (called condensers), with the phase change
usually occurring on the shell side. Boilers in steam engine locomotives are
typically large, usually cylindrically-shaped shell-and-tube heat exchangers. In
large power plants with steam-driven turbines, shell-and-tube surface condensers
are used to condense the exhaust steam exiting the turbine into condensate
water which is recycled back to be turned into steam in the steam generator.
Among shell and tube heat exchangers the different types are:
U tube heat exchangers.
Straight tube heat exchanger- one pass and two pass.
Fig: 27
Fig: 28
Fig: 29
PIPELINES:
Pipeline transport is the transportation of goods through a pipe. Most commonly,
liquid and gases are sent, but pneumatic tubes that transport solid capsules using
compressed air are also used.As for gases and liquids, any chemically stable
substance can be sent through a pipeline. Therefore sewage, slurry, water, or
even beer pipelines exist; but arguably the most valuable are those transporting
fuels: oil (oleoduct), natural gas (gas grid) and biofuels.
Pipelines are mainly used for transportation of:
Water
Crude oil
Hydrogen gas
Finished product
AN OVERVIEW OF PIPELINES
Fig: 30
CONTROL SYSTEMS:
In the plant two types of control system is mainly used:
1. Distributed control systems (DCS)
2. Programmable logic control (PLC)
A DCS typically uses custom designed processors as controllers and uses both
proprietary interconnections and communications protocol for communication.
Input and output modules form component parts of the DCS. Distributed Control
Systems (DCSs) are dedicated systems used to control manufacturing processes
that are continuous or batch-oriented, such as oil refining, petrochemicals, central
station power generation, pharmaceuticals, food & beverage manufacturing,
cement production, steelmaking, and papermaking. DCSs are connected to
sensors and actuators and use setpoint control to control the flow of material
through the plant. The most common example is a setpoint control loop
consisting of a pressure sensor, controller, and control valve.
OVERVIEW OF DCS
ARRAGEMENTS
Fig: 31
PLC
ARRANGEMENTS
Fig: 32
CONCLUSION:
CONCLUSION:
FCCU is the most profitable unit in refinery and CRU is the next more
profitable.
A new Hydrocracker project is also under operation.
LPG bottling plant has been shifted to outside in refinery for safety
purpose.
DECLARATION
It was a learning experience for us. Not only did we learn about
the details of the refining processes but also acquired
knowledge about the proper mechanical operations of various
equipments. The training provided us with the insight of how a
refinery operates with the proper co-ordination between the
management and the grass root level.