Indian Oil Corporation LtdCompany HistoryThe Indian Oil Corporation Ltd operates as the largest company in India in terms of turnover and is the only Indian company to rank in the Fortune Global 500 listing The oil concern is administratively controlled by Indias Ministry of Petroleum and Natural Gas a government entity that owns just over 90 percent of the firm Since 1959 this refining marketing and international trading company served the Indian state with the important task of reducing Indias dependence on foreign oil and thus conserving valuable foreign exchange That changed in April 2002 however when the Indian government deregulated its petroleum industry and ended Indian Oils monopoly on crude oil imports The firm owns and operates seven of the 17 refineries in India controlling nearly 40 percent of the countrys refining capacity

IndianOil Major ProjectsIndianOil continues to lay emphasis on infrastructure development Towards this end a number of schemes have been initiated with increasing emphasis on project execution in compressed schedules as per world benchmarking standards Schemes for improvement and increased profitability through debottlenecking modifications introduction of value added products are being taken up in addition to grassroots facilities Project systems have been streamlined in line with ISO standards

1 GRASSROOTS REFINERY PROJECT AT PARADIP (ORISSA)2 RESIDUE UPGRADATION AND MSHSD QUALITY IMPROVEMENT

PROJECT AT GUJARAT REFINERY3 NAPHTHA CRACKER AND POLYMER COMPLEX AT PANIPAT

(HARYANA)4 MS QUALITY UPGRADATION PROJECT BARAUNI REFINERY (BIHAR)5 MS QUALITY UPGRADATION PROJECT AT GUWAHATI REFINERY

(ASSAM)6 MS QUALITY UPGRADATION PROJECT AT DIGBOI REFINERY (ASSAM)7 DADRI-PANIPAT R-LNG SPUR PIPELINE8 PANIPAT REFINERY EXPANSION FROM 12 MMTPA TO 15 MMTPA9 BRANCH PIPELINE FROM KSPL VIRAMGAM TO KANDLA10 DIESEL HYDRO-TREATMENT (DHDT) PROJECT AT BONGAIGAON

REFINERY (ASSAM)11 MS QUALITY UPGRADATION PROJECT AT BONGAIGAON

REFINERY (ASSAM)12 PARADIP-NEW SAMBALPUR-RAIPUR-RANCHI PIPELINES13 DE-BOTTLENECKING OF SALAYA-MATHURA CRUDE PIPLEINE

14 INTEGRATED CRUDE OIL HANDLING FACILITIES AT PARADIP

Down the memory lane

1965 Barauni Refinery being dedicated to the nation by Prof Humayun Kabir Honrsquoble Minister of Petroleum amp Chemicals in the presence of a huge gathering

at the foundation site BR Campus on 15th January 1965

BARAUNI REFINERYBarauni Refinery is the second public sector refinery of the Indian Oil Corporation Limited which was set-up under the collaboration of erstwhile USSR and limited participation of Romania It is located near the northern bank of the river Ganga at Begusarai District town of Bihar state The refinery is strategically located on the crossroads of two important national highways NH-30 and NH-31 and two important railways Eastern Railways and North Eastern Railways The river Ganga flows around 8 km from the refinery

Barauni Refinery is one of the biggest size oil refinery owned and managed by IOCL The refinery is located about 8km from the town Begusarai and is surrounded by villages It started with a refining capacity of processing 2 Million Metric Tonnes Per Annum of Assam Crude through the Nahar-Katiya-Barauni pipeline The Barauni Refinery takes its crude oil from foreign countries through Barauni - Haldia Crude Pipeline (BHCPL)

Indian Oil is the highest ranked Indian company in the prestigious Fortune Global 500 listing having moved up 19 places to the 116th position in 2008 It is also the 18th largest petroleum company in the world

AwardsAccolades Barauni Refinery achieved safety award in gold category

of ldquoGreen Tech Foundation Safety Awardrdquo on 040509 BR bagged 2nd prize in Golden Jubilee Indian Oil Album in

Aug 09 Barauni Refinery accredited in Oct 09 with prestigious

ldquoJawaharlal Nehru Centenary Awardsrdquo (3rd prize) for Energy Performance in Refinery for

the year 2008-09 by MoPNGo Suggestion Fortnight declared and inaugurated by

ED BR on 091209o Barauni Refinery has been accredited first prize in

the refinery sector for ldquoNational Energy Conservation Awards-2009rdquo by Ministry of Power Award

received by ED BR on 141209

Barauni Refinery was initially designed to process low sulphur crude oil (sweet crude) of Assam After establishment of other refineries in the Northeast Assam crude is unavailable for Barauni Hence sweet crude is being sourced from African South East Asian and Middle East countries like Nigeria Iraq amp Malaysia The refinery receives crude oil by pipeline from Paradip on the east coast via Haldia With various revamps and expansion projects at Barauni Refinery capability for processing high-sulphur crude has been added mdash high-sulphur crude oil (sour crude) is cheaper than lowsulphur crudes mdash thereby increasing not only the capacity but also the profitability of the refinery

Crude oil is separated into fractions by fractional distillation The fractions at the top of the fractionating column have lower boiling points than the fractions at the bottom The heavy bottom fractions are often cracked into lighter more useful products All of the fractions are processed further in other refining unitsDifferent boiling points allow the hydrocarbons to be separated by distillation Since the lighter liquid products are in great demand for use ininternal combustion engines a modern refinery will convert heavy hydrocarbons and lighter gaseous elements into these higher value products

Oil can be used in a variety of ways because it contains hydrocarbons ofvarying molecular masses forms and lengths such as paraffins aromatics naphthenes (or cycloalkanes) alkenes dienes and alkynes While the molecules in crude oil include different atoms such as sulfur and nitrogen the hydrocarbons are the most common form of molecules which are molecules of varying lengths and complexity made of hydrogen and carbon atoms and a small number of oxygen atoms The differences in the structure of these molecules account for their varying

physical and chemical properties and it is this variety that makes crude oil useful in a broad range of applications

Once separated and purified of any contaminants and impurities the fuel or lubricant can be sold without further processing Smaller molecules such as isobutane and propylene or butylenes can be recombined to meet specific octane requirements by processes such as alkylation or less commonly dimerization Octane grade of gasoline can also be improved by catalytic reforming which involves removing hydrogen from hydrocarbons producing compounds with higher octane ratings such as aromatics Intermediate products such as gasoils can even be reprocessed to break a heavy longchained oil into a lighter short-chained one by various forms of cracking such as fluid catalytic cracking thermal cracking and hydrocracking The final step in gasoline production is the blending of fuels with different octane ratings vapor pressures and other properties to meet product specifications

HIGHLIGHTS Barauni Refinery achieved highest ever crude processing

of 62 MMT (outlook) during the year Previous best was 594 MMT during the year 2008-09

Achieved highest ever Low Sulphur crude processing of 555 MMT (outlook) during the year surpassing the previous best of 516 MMT during the year 2008-09

Achieved highest ever CRU throughput of 2883 TMT (outlook) Previous best was 277 TMT during the year 1999-00

Achieved highest ever RFCCU throughput of 1497 MMT (outlook) during the year surpassing previous best of 1454 MMT during the year 2008-09

Atmospheric and Vacuum Distillation Unit (AVU-I II)

INTRODUCTION There are two Atmospheric and Vacuum Distillation Units

in Barauni Refinery numbered as AVU-I and AVU-II each were designed for 1 MMTyear crude processing Subsequently another distillation unit without vacuum distillation facility was added This unit was designed for 1 MMTyear of crude and known as AU-3 Crude Processing capacity of both units AVU-I amp AVU-II was increased to 16 MMTyear by HETO project (Heat Exchanger Train optimization) in 1990 The above modification (HETO project job was designed by EIL (Engineers India Limited) and fabricationerection job was completed by Ms PETHON ENGG LTD Mumbai The units were again revamped in 1998 (M amp I) when the capacity was expanded to 21 MMTyear of each of the two units

Through these units were designed on the basis of evaluation data of Naharkatiya crude presently the units have switched on to imported crude due to none availability of Assam crude

PROCESS DESCRIPTION Crude oil (imported) is received from Haldia by pipeline

and is pumped from tanks through Heat Exchangers after exchanging heat with various hot stream the crude streams attain a temperature of approx 120oC to 130oC

After attaining temperature about 120oC to 130oC the two crude flows combine together and enter in Desalter for separation and removal of water and salt

Bi electric desalter is having two energised electrodes A distributor head splits crude between the upper and lower pair of electrodes Crude oil separated from water between the centre and lower electrodes passes through the upper electrode in a converging countercurrent flow with the separating water from upper set of electrodes This creates a second washing zone for half of the feed in a strong electrical field thereby causing maximum salt removal efficiency The two desalter in AVU-I ampII are

PETRECO BIELECTRIC type which were commissioned in the year 2001

POST DESALTER- At the outlet of Desalter there are two booster pumps which boost up the crude at discharge pressure around 15 kgkm2 Pre-topping column has 20 Trays (All valve trays with a bed of packing between 9th

amp 10th tray) and operates operating conditions

Pretopped crude stream passes through heat exchangers

After exchanging heat with various hot products the pretopped crude flows combine and it is segregated again near furnace in two pass flows before entering the atmospheric heater for further heating and finally fed to 6th

tray of main column through two entry nozzles at 340oCThe Furnace is provided with Air Preheater

Main Fractionating Column has 43 double pass valve trays Following are the operating parameters of the main column

As per design two types of gas oil one light and other heavy were supposed to be withdrawn light gas oil from 6th

and 18th

tray and heavy gas oil from 8th10th trays at 140-300oC and 300-350oC respectively At present gas oil is withdrawn as 250-370oC cut from 16th18th

tray The existing 7th to 14th double pass

channel trays were replaced with valve trays in HETO 1990 Since 1970 heavy gas oil withdrawal was stopped Main Column bottom is feed to vacuum column

VACUUM DISTILLATION - Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure) causing evaporation of the most volatile liquid(s) (those with the lowest boiling points) This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure Vacuum distillation is used with or without heating the solution

Vacuum distillation increases the relative volatility of the key components in many applications The higher the relative volatility the more separable are the two components this connotes fewer stages in a distillation column in order to effect the same separation between the overhead and bottoms products Lower pressures increase relative volatilities in most systems

A second advantage of vacuum distillation is the reduced temperaturerequirement at lower pressures For many systems the products degrade or polymerize at elevated temperatures

Vacuum distillation can improve a separation by Prevention of product degradation or polymer formation

because of reduced pressure leading to lower tower bottoms temperatures

Reduction of product degradation or polymer formation because of reduced mean residence time especially in columns using packing rather than trays

Increasing capacity yield and purity

Another advantage of vacuum distillation is the reduced capital cost at the expense of slightly more operating cost Utilizing vacuum distillation can reduce the height and diameter and thus the capital cost of a distillation column

Reduced crude from main column bottom at a temperature of approx 330oC is pumped through Furnace The Furnace coil outlet (4 passes) combines in one header

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

The f1 Theexemp

Cytic reery napucts calknown aydrocarof theuct refoes havinstock Iocarbonogen gasrn petrane ethreactionhe reacture ofming ustions raures ofcommonatinum ar and niytic refh removfour maje dehydplified

CRU(Cforminghthasled refas petrorbon momolecuormateng higheIn so do

n molecus for usoleum rhane prn chemtions ochydrogsed as wange frof aboutly usedandortrogenformeres bothjor catadrogenain the c

CATAg is a chtypicallormateol) Basoleculesules intocontainer octanoing theules andse in a nrefineryropanemistryccur in ten Depwell as tom tem5 to 45catalytrheniumcompouis alway

h the sualytic ration ofconvers

ALYTIhemically havines whichsically ts in theo smallens hydrne valuee proced produnumbery Otheand butthe prependingthe desmperatu5 atmtic refom whichunds Tys preulfuranreformif naphtsion met

IC REl procesng low oh are cothe proe naphther molecocarboes thaness sepa

uces verr of theer byprotanesesence oupon tsired reres of aormingh are veTherefoprocessnd the nng reacthenesthylcyc

EFORss usedoctane romponecess reha feedcules Tns withthe hyarates hry signie otheroductsof a cathe typeeactionabout 4catalysery susre thesed in anitrogenctions ato convclohexan

RMINd to conratingsents ofe-arrangdstocksThe oveh more cydrocarhydrogeficant aprocessare smatalyst ae or verseverit495 to 5sts consceptibnaphthhydron compoare-vert thene (a na

NG UNnvert pe into hihigh-ocges or ras welerall effcomplexbons inen atomamountses invoall amouand a hirsion ofty the

525 degCtain noble to poha feeddesulfuoundsem intoaphthen

NIT)etroleumigh-octctane gare-strul as brefect is tx molecthe nams froms of byolved inunts ofgh partf catalyreactioand froble metoisoningdstock turizatioaromatne) to tmane liquasolineuctureseakingthat thcularphtham theyproducn a

ftialticonomtals sucg byto aon unittics astolueneuidhetch-2 Thethe coshown3 The(commnorma4 Thethe crThe hreforparafdehydprodureforof hydfeedsTypicThe onapht(petrohydroreforwith adifferdegC ande isome

onversin belowe dehydmonly caal heptae hydrorackinghydrocrming refins dodrogenauce hydrming ofdrogenstockal naphoverheatha andol) prododesulfumer tohigherrent hyd a finaerizatioon of ndrogenaalled deane to tocrackinof norrackingeactionses not cation ofrogen Tf petrolgas (aththa fead liquidwill bec

duct afturizer treformr octanydrocaral boilingon of noormal oation aehydroctolueneng of pmal hepof paras that cconsumf naphthThe oveleum nat 0 degC aeedstocd distillacome ater it isto remom its hye ratingbon comg pointormal poctane tnd aromcyclizat as shoparaffinptane inaffins isconsumeme or prhenes aerall neaphthas

nd 1 atmcksate fromajors furtheove sulfydrocarbg valuempoundof aboparaffinto 25-Dmatizattion) asown belons intonto isops the ones hydrroduce hand theet produs rangesm) perm atmocomponer procfur-contbon mo The nas It haut 200ns to isDimethytion ofexempowsmallerpentanenly onerogen Thydroge

dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

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T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

14 INTEGRATED CRUDE OIL HANDLING FACILITIES AT PARADIP

Down the memory lane

1965 Barauni Refinery being dedicated to the nation by Prof Humayun Kabir Honrsquoble Minister of Petroleum amp Chemicals in the presence of a huge gathering

at the foundation site BR Campus on 15th January 1965

BARAUNI REFINERYBarauni Refinery is the second public sector refinery of the Indian Oil Corporation Limited which was set-up under the collaboration of erstwhile USSR and limited participation of Romania It is located near the northern bank of the river Ganga at Begusarai District town of Bihar state The refinery is strategically located on the crossroads of two important national highways NH-30 and NH-31 and two important railways Eastern Railways and North Eastern Railways The river Ganga flows around 8 km from the refinery

Barauni Refinery is one of the biggest size oil refinery owned and managed by IOCL The refinery is located about 8km from the town Begusarai and is surrounded by villages It started with a refining capacity of processing 2 Million Metric Tonnes Per Annum of Assam Crude through the Nahar-Katiya-Barauni pipeline The Barauni Refinery takes its crude oil from foreign countries through Barauni - Haldia Crude Pipeline (BHCPL)

Indian Oil is the highest ranked Indian company in the prestigious Fortune Global 500 listing having moved up 19 places to the 116th position in 2008 It is also the 18th largest petroleum company in the world

AwardsAccolades Barauni Refinery achieved safety award in gold category

of ldquoGreen Tech Foundation Safety Awardrdquo on 040509 BR bagged 2nd prize in Golden Jubilee Indian Oil Album in

Aug 09 Barauni Refinery accredited in Oct 09 with prestigious

ldquoJawaharlal Nehru Centenary Awardsrdquo (3rd prize) for Energy Performance in Refinery for

the year 2008-09 by MoPNGo Suggestion Fortnight declared and inaugurated by

ED BR on 091209o Barauni Refinery has been accredited first prize in

the refinery sector for ldquoNational Energy Conservation Awards-2009rdquo by Ministry of Power Award

received by ED BR on 141209

Barauni Refinery was initially designed to process low sulphur crude oil (sweet crude) of Assam After establishment of other refineries in the Northeast Assam crude is unavailable for Barauni Hence sweet crude is being sourced from African South East Asian and Middle East countries like Nigeria Iraq amp Malaysia The refinery receives crude oil by pipeline from Paradip on the east coast via Haldia With various revamps and expansion projects at Barauni Refinery capability for processing high-sulphur crude has been added mdash high-sulphur crude oil (sour crude) is cheaper than lowsulphur crudes mdash thereby increasing not only the capacity but also the profitability of the refinery

Crude oil is separated into fractions by fractional distillation The fractions at the top of the fractionating column have lower boiling points than the fractions at the bottom The heavy bottom fractions are often cracked into lighter more useful products All of the fractions are processed further in other refining unitsDifferent boiling points allow the hydrocarbons to be separated by distillation Since the lighter liquid products are in great demand for use ininternal combustion engines a modern refinery will convert heavy hydrocarbons and lighter gaseous elements into these higher value products

Oil can be used in a variety of ways because it contains hydrocarbons ofvarying molecular masses forms and lengths such as paraffins aromatics naphthenes (or cycloalkanes) alkenes dienes and alkynes While the molecules in crude oil include different atoms such as sulfur and nitrogen the hydrocarbons are the most common form of molecules which are molecules of varying lengths and complexity made of hydrogen and carbon atoms and a small number of oxygen atoms The differences in the structure of these molecules account for their varying

physical and chemical properties and it is this variety that makes crude oil useful in a broad range of applications

Once separated and purified of any contaminants and impurities the fuel or lubricant can be sold without further processing Smaller molecules such as isobutane and propylene or butylenes can be recombined to meet specific octane requirements by processes such as alkylation or less commonly dimerization Octane grade of gasoline can also be improved by catalytic reforming which involves removing hydrogen from hydrocarbons producing compounds with higher octane ratings such as aromatics Intermediate products such as gasoils can even be reprocessed to break a heavy longchained oil into a lighter short-chained one by various forms of cracking such as fluid catalytic cracking thermal cracking and hydrocracking The final step in gasoline production is the blending of fuels with different octane ratings vapor pressures and other properties to meet product specifications

HIGHLIGHTS Barauni Refinery achieved highest ever crude processing

of 62 MMT (outlook) during the year Previous best was 594 MMT during the year 2008-09

Achieved highest ever Low Sulphur crude processing of 555 MMT (outlook) during the year surpassing the previous best of 516 MMT during the year 2008-09

Achieved highest ever CRU throughput of 2883 TMT (outlook) Previous best was 277 TMT during the year 1999-00

Achieved highest ever RFCCU throughput of 1497 MMT (outlook) during the year surpassing previous best of 1454 MMT during the year 2008-09

Atmospheric and Vacuum Distillation Unit (AVU-I II)

INTRODUCTION There are two Atmospheric and Vacuum Distillation Units

in Barauni Refinery numbered as AVU-I and AVU-II each were designed for 1 MMTyear crude processing Subsequently another distillation unit without vacuum distillation facility was added This unit was designed for 1 MMTyear of crude and known as AU-3 Crude Processing capacity of both units AVU-I amp AVU-II was increased to 16 MMTyear by HETO project (Heat Exchanger Train optimization) in 1990 The above modification (HETO project job was designed by EIL (Engineers India Limited) and fabricationerection job was completed by Ms PETHON ENGG LTD Mumbai The units were again revamped in 1998 (M amp I) when the capacity was expanded to 21 MMTyear of each of the two units

Through these units were designed on the basis of evaluation data of Naharkatiya crude presently the units have switched on to imported crude due to none availability of Assam crude

PROCESS DESCRIPTION Crude oil (imported) is received from Haldia by pipeline

and is pumped from tanks through Heat Exchangers after exchanging heat with various hot stream the crude streams attain a temperature of approx 120oC to 130oC

After attaining temperature about 120oC to 130oC the two crude flows combine together and enter in Desalter for separation and removal of water and salt

Bi electric desalter is having two energised electrodes A distributor head splits crude between the upper and lower pair of electrodes Crude oil separated from water between the centre and lower electrodes passes through the upper electrode in a converging countercurrent flow with the separating water from upper set of electrodes This creates a second washing zone for half of the feed in a strong electrical field thereby causing maximum salt removal efficiency The two desalter in AVU-I ampII are

PETRECO BIELECTRIC type which were commissioned in the year 2001

POST DESALTER- At the outlet of Desalter there are two booster pumps which boost up the crude at discharge pressure around 15 kgkm2 Pre-topping column has 20 Trays (All valve trays with a bed of packing between 9th

amp 10th tray) and operates operating conditions

Pretopped crude stream passes through heat exchangers

After exchanging heat with various hot products the pretopped crude flows combine and it is segregated again near furnace in two pass flows before entering the atmospheric heater for further heating and finally fed to 6th

tray of main column through two entry nozzles at 340oCThe Furnace is provided with Air Preheater

Main Fractionating Column has 43 double pass valve trays Following are the operating parameters of the main column

As per design two types of gas oil one light and other heavy were supposed to be withdrawn light gas oil from 6th

and 18th

tray and heavy gas oil from 8th10th trays at 140-300oC and 300-350oC respectively At present gas oil is withdrawn as 250-370oC cut from 16th18th

tray The existing 7th to 14th double pass

channel trays were replaced with valve trays in HETO 1990 Since 1970 heavy gas oil withdrawal was stopped Main Column bottom is feed to vacuum column

VACUUM DISTILLATION - Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure) causing evaporation of the most volatile liquid(s) (those with the lowest boiling points) This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure Vacuum distillation is used with or without heating the solution

Vacuum distillation increases the relative volatility of the key components in many applications The higher the relative volatility the more separable are the two components this connotes fewer stages in a distillation column in order to effect the same separation between the overhead and bottoms products Lower pressures increase relative volatilities in most systems

A second advantage of vacuum distillation is the reduced temperaturerequirement at lower pressures For many systems the products degrade or polymerize at elevated temperatures

Vacuum distillation can improve a separation by Prevention of product degradation or polymer formation

because of reduced pressure leading to lower tower bottoms temperatures

Reduction of product degradation or polymer formation because of reduced mean residence time especially in columns using packing rather than trays

Increasing capacity yield and purity

Another advantage of vacuum distillation is the reduced capital cost at the expense of slightly more operating cost Utilizing vacuum distillation can reduce the height and diameter and thus the capital cost of a distillation column

Reduced crude from main column bottom at a temperature of approx 330oC is pumped through Furnace The Furnace coil outlet (4 passes) combines in one header

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

BARAUNI REFINERYBarauni Refinery is the second public sector refinery of the Indian Oil Corporation Limited which was set-up under the collaboration of erstwhile USSR and limited participation of Romania It is located near the northern bank of the river Ganga at Begusarai District town of Bihar state The refinery is strategically located on the crossroads of two important national highways NH-30 and NH-31 and two important railways Eastern Railways and North Eastern Railways The river Ganga flows around 8 km from the refinery

Barauni Refinery is one of the biggest size oil refinery owned and managed by IOCL The refinery is located about 8km from the town Begusarai and is surrounded by villages It started with a refining capacity of processing 2 Million Metric Tonnes Per Annum of Assam Crude through the Nahar-Katiya-Barauni pipeline The Barauni Refinery takes its crude oil from foreign countries through Barauni - Haldia Crude Pipeline (BHCPL)

Indian Oil is the highest ranked Indian company in the prestigious Fortune Global 500 listing having moved up 19 places to the 116th position in 2008 It is also the 18th largest petroleum company in the world

AwardsAccolades Barauni Refinery achieved safety award in gold category

of ldquoGreen Tech Foundation Safety Awardrdquo on 040509 BR bagged 2nd prize in Golden Jubilee Indian Oil Album in

Aug 09 Barauni Refinery accredited in Oct 09 with prestigious

ldquoJawaharlal Nehru Centenary Awardsrdquo (3rd prize) for Energy Performance in Refinery for

the year 2008-09 by MoPNGo Suggestion Fortnight declared and inaugurated by

ED BR on 091209o Barauni Refinery has been accredited first prize in

the refinery sector for ldquoNational Energy Conservation Awards-2009rdquo by Ministry of Power Award

received by ED BR on 141209

Barauni Refinery was initially designed to process low sulphur crude oil (sweet crude) of Assam After establishment of other refineries in the Northeast Assam crude is unavailable for Barauni Hence sweet crude is being sourced from African South East Asian and Middle East countries like Nigeria Iraq amp Malaysia The refinery receives crude oil by pipeline from Paradip on the east coast via Haldia With various revamps and expansion projects at Barauni Refinery capability for processing high-sulphur crude has been added mdash high-sulphur crude oil (sour crude) is cheaper than lowsulphur crudes mdash thereby increasing not only the capacity but also the profitability of the refinery

Crude oil is separated into fractions by fractional distillation The fractions at the top of the fractionating column have lower boiling points than the fractions at the bottom The heavy bottom fractions are often cracked into lighter more useful products All of the fractions are processed further in other refining unitsDifferent boiling points allow the hydrocarbons to be separated by distillation Since the lighter liquid products are in great demand for use ininternal combustion engines a modern refinery will convert heavy hydrocarbons and lighter gaseous elements into these higher value products

Oil can be used in a variety of ways because it contains hydrocarbons ofvarying molecular masses forms and lengths such as paraffins aromatics naphthenes (or cycloalkanes) alkenes dienes and alkynes While the molecules in crude oil include different atoms such as sulfur and nitrogen the hydrocarbons are the most common form of molecules which are molecules of varying lengths and complexity made of hydrogen and carbon atoms and a small number of oxygen atoms The differences in the structure of these molecules account for their varying

physical and chemical properties and it is this variety that makes crude oil useful in a broad range of applications

Once separated and purified of any contaminants and impurities the fuel or lubricant can be sold without further processing Smaller molecules such as isobutane and propylene or butylenes can be recombined to meet specific octane requirements by processes such as alkylation or less commonly dimerization Octane grade of gasoline can also be improved by catalytic reforming which involves removing hydrogen from hydrocarbons producing compounds with higher octane ratings such as aromatics Intermediate products such as gasoils can even be reprocessed to break a heavy longchained oil into a lighter short-chained one by various forms of cracking such as fluid catalytic cracking thermal cracking and hydrocracking The final step in gasoline production is the blending of fuels with different octane ratings vapor pressures and other properties to meet product specifications

HIGHLIGHTS Barauni Refinery achieved highest ever crude processing

of 62 MMT (outlook) during the year Previous best was 594 MMT during the year 2008-09

Achieved highest ever Low Sulphur crude processing of 555 MMT (outlook) during the year surpassing the previous best of 516 MMT during the year 2008-09

Achieved highest ever CRU throughput of 2883 TMT (outlook) Previous best was 277 TMT during the year 1999-00

Achieved highest ever RFCCU throughput of 1497 MMT (outlook) during the year surpassing previous best of 1454 MMT during the year 2008-09

Atmospheric and Vacuum Distillation Unit (AVU-I II)

INTRODUCTION There are two Atmospheric and Vacuum Distillation Units

in Barauni Refinery numbered as AVU-I and AVU-II each were designed for 1 MMTyear crude processing Subsequently another distillation unit without vacuum distillation facility was added This unit was designed for 1 MMTyear of crude and known as AU-3 Crude Processing capacity of both units AVU-I amp AVU-II was increased to 16 MMTyear by HETO project (Heat Exchanger Train optimization) in 1990 The above modification (HETO project job was designed by EIL (Engineers India Limited) and fabricationerection job was completed by Ms PETHON ENGG LTD Mumbai The units were again revamped in 1998 (M amp I) when the capacity was expanded to 21 MMTyear of each of the two units

Through these units were designed on the basis of evaluation data of Naharkatiya crude presently the units have switched on to imported crude due to none availability of Assam crude

PROCESS DESCRIPTION Crude oil (imported) is received from Haldia by pipeline

and is pumped from tanks through Heat Exchangers after exchanging heat with various hot stream the crude streams attain a temperature of approx 120oC to 130oC

After attaining temperature about 120oC to 130oC the two crude flows combine together and enter in Desalter for separation and removal of water and salt

Bi electric desalter is having two energised electrodes A distributor head splits crude between the upper and lower pair of electrodes Crude oil separated from water between the centre and lower electrodes passes through the upper electrode in a converging countercurrent flow with the separating water from upper set of electrodes This creates a second washing zone for half of the feed in a strong electrical field thereby causing maximum salt removal efficiency The two desalter in AVU-I ampII are

PETRECO BIELECTRIC type which were commissioned in the year 2001

POST DESALTER- At the outlet of Desalter there are two booster pumps which boost up the crude at discharge pressure around 15 kgkm2 Pre-topping column has 20 Trays (All valve trays with a bed of packing between 9th

amp 10th tray) and operates operating conditions

Pretopped crude stream passes through heat exchangers

After exchanging heat with various hot products the pretopped crude flows combine and it is segregated again near furnace in two pass flows before entering the atmospheric heater for further heating and finally fed to 6th

tray of main column through two entry nozzles at 340oCThe Furnace is provided with Air Preheater

Main Fractionating Column has 43 double pass valve trays Following are the operating parameters of the main column

As per design two types of gas oil one light and other heavy were supposed to be withdrawn light gas oil from 6th

and 18th

tray and heavy gas oil from 8th10th trays at 140-300oC and 300-350oC respectively At present gas oil is withdrawn as 250-370oC cut from 16th18th

tray The existing 7th to 14th double pass

channel trays were replaced with valve trays in HETO 1990 Since 1970 heavy gas oil withdrawal was stopped Main Column bottom is feed to vacuum column

VACUUM DISTILLATION - Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure) causing evaporation of the most volatile liquid(s) (those with the lowest boiling points) This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure Vacuum distillation is used with or without heating the solution

Vacuum distillation increases the relative volatility of the key components in many applications The higher the relative volatility the more separable are the two components this connotes fewer stages in a distillation column in order to effect the same separation between the overhead and bottoms products Lower pressures increase relative volatilities in most systems

A second advantage of vacuum distillation is the reduced temperaturerequirement at lower pressures For many systems the products degrade or polymerize at elevated temperatures

Vacuum distillation can improve a separation by Prevention of product degradation or polymer formation

because of reduced pressure leading to lower tower bottoms temperatures

Reduction of product degradation or polymer formation because of reduced mean residence time especially in columns using packing rather than trays

Increasing capacity yield and purity

Another advantage of vacuum distillation is the reduced capital cost at the expense of slightly more operating cost Utilizing vacuum distillation can reduce the height and diameter and thus the capital cost of a distillation column

Reduced crude from main column bottom at a temperature of approx 330oC is pumped through Furnace The Furnace coil outlet (4 passes) combines in one header

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

The f1 Theexemp

Cytic reery napucts calknown aydrocarof theuct refoes havinstock Iocarbonogen gasrn petrane ethreactionhe reacture ofming ustions raures ofcommonatinum ar and niytic refh removfour maje dehydplified

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CATAg is a chtypicallormateol) Basoleculesules intocontainer octanoing theules andse in a nrefineryropanemistryccur in ten Depwell as tom tem5 to 45catalytrheniumcompouis alway

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NIT)etroleumigh-octctane gare-strul as brefect is tx molecthe nams froms of byolved inunts ofgh partf catalyreactioand froble metoisoningdstock turizatioaromatne) to tmane liquasolineuctureseakingthat thcularphtham theyproducn a

ftialticonomtals sucg byto aon unittics astolueneuidhetch-2 Thethe coshown3 The(commnorma4 Thethe crThe hreforparafdehydprodureforof hydfeedsTypicThe onapht(petrohydroreforwith adifferdegC ande isome

onversin belowe dehydmonly caal heptae hydrorackinghydrocrming refins dodrogenauce hydrming ofdrogenstockal naphoverheatha andol) prododesulfumer tohigherrent hyd a finaerizatioon of ndrogenaalled deane to tocrackinof norrackingeactionses not cation ofrogen Tf petrolgas (aththa fead liquidwill bec

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dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Barauni Refinery was initially designed to process low sulphur crude oil (sweet crude) of Assam After establishment of other refineries in the Northeast Assam crude is unavailable for Barauni Hence sweet crude is being sourced from African South East Asian and Middle East countries like Nigeria Iraq amp Malaysia The refinery receives crude oil by pipeline from Paradip on the east coast via Haldia With various revamps and expansion projects at Barauni Refinery capability for processing high-sulphur crude has been added mdash high-sulphur crude oil (sour crude) is cheaper than lowsulphur crudes mdash thereby increasing not only the capacity but also the profitability of the refinery

Crude oil is separated into fractions by fractional distillation The fractions at the top of the fractionating column have lower boiling points than the fractions at the bottom The heavy bottom fractions are often cracked into lighter more useful products All of the fractions are processed further in other refining unitsDifferent boiling points allow the hydrocarbons to be separated by distillation Since the lighter liquid products are in great demand for use ininternal combustion engines a modern refinery will convert heavy hydrocarbons and lighter gaseous elements into these higher value products

Oil can be used in a variety of ways because it contains hydrocarbons ofvarying molecular masses forms and lengths such as paraffins aromatics naphthenes (or cycloalkanes) alkenes dienes and alkynes While the molecules in crude oil include different atoms such as sulfur and nitrogen the hydrocarbons are the most common form of molecules which are molecules of varying lengths and complexity made of hydrogen and carbon atoms and a small number of oxygen atoms The differences in the structure of these molecules account for their varying

physical and chemical properties and it is this variety that makes crude oil useful in a broad range of applications

Once separated and purified of any contaminants and impurities the fuel or lubricant can be sold without further processing Smaller molecules such as isobutane and propylene or butylenes can be recombined to meet specific octane requirements by processes such as alkylation or less commonly dimerization Octane grade of gasoline can also be improved by catalytic reforming which involves removing hydrogen from hydrocarbons producing compounds with higher octane ratings such as aromatics Intermediate products such as gasoils can even be reprocessed to break a heavy longchained oil into a lighter short-chained one by various forms of cracking such as fluid catalytic cracking thermal cracking and hydrocracking The final step in gasoline production is the blending of fuels with different octane ratings vapor pressures and other properties to meet product specifications

HIGHLIGHTS Barauni Refinery achieved highest ever crude processing

of 62 MMT (outlook) during the year Previous best was 594 MMT during the year 2008-09

Achieved highest ever Low Sulphur crude processing of 555 MMT (outlook) during the year surpassing the previous best of 516 MMT during the year 2008-09

Achieved highest ever CRU throughput of 2883 TMT (outlook) Previous best was 277 TMT during the year 1999-00

Achieved highest ever RFCCU throughput of 1497 MMT (outlook) during the year surpassing previous best of 1454 MMT during the year 2008-09

Atmospheric and Vacuum Distillation Unit (AVU-I II)

INTRODUCTION There are two Atmospheric and Vacuum Distillation Units

in Barauni Refinery numbered as AVU-I and AVU-II each were designed for 1 MMTyear crude processing Subsequently another distillation unit without vacuum distillation facility was added This unit was designed for 1 MMTyear of crude and known as AU-3 Crude Processing capacity of both units AVU-I amp AVU-II was increased to 16 MMTyear by HETO project (Heat Exchanger Train optimization) in 1990 The above modification (HETO project job was designed by EIL (Engineers India Limited) and fabricationerection job was completed by Ms PETHON ENGG LTD Mumbai The units were again revamped in 1998 (M amp I) when the capacity was expanded to 21 MMTyear of each of the two units

Through these units were designed on the basis of evaluation data of Naharkatiya crude presently the units have switched on to imported crude due to none availability of Assam crude

PROCESS DESCRIPTION Crude oil (imported) is received from Haldia by pipeline

and is pumped from tanks through Heat Exchangers after exchanging heat with various hot stream the crude streams attain a temperature of approx 120oC to 130oC

After attaining temperature about 120oC to 130oC the two crude flows combine together and enter in Desalter for separation and removal of water and salt

Bi electric desalter is having two energised electrodes A distributor head splits crude between the upper and lower pair of electrodes Crude oil separated from water between the centre and lower electrodes passes through the upper electrode in a converging countercurrent flow with the separating water from upper set of electrodes This creates a second washing zone for half of the feed in a strong electrical field thereby causing maximum salt removal efficiency The two desalter in AVU-I ampII are

PETRECO BIELECTRIC type which were commissioned in the year 2001

POST DESALTER- At the outlet of Desalter there are two booster pumps which boost up the crude at discharge pressure around 15 kgkm2 Pre-topping column has 20 Trays (All valve trays with a bed of packing between 9th

amp 10th tray) and operates operating conditions

Pretopped crude stream passes through heat exchangers

After exchanging heat with various hot products the pretopped crude flows combine and it is segregated again near furnace in two pass flows before entering the atmospheric heater for further heating and finally fed to 6th

tray of main column through two entry nozzles at 340oCThe Furnace is provided with Air Preheater

Main Fractionating Column has 43 double pass valve trays Following are the operating parameters of the main column

As per design two types of gas oil one light and other heavy were supposed to be withdrawn light gas oil from 6th

and 18th

tray and heavy gas oil from 8th10th trays at 140-300oC and 300-350oC respectively At present gas oil is withdrawn as 250-370oC cut from 16th18th

tray The existing 7th to 14th double pass

channel trays were replaced with valve trays in HETO 1990 Since 1970 heavy gas oil withdrawal was stopped Main Column bottom is feed to vacuum column

VACUUM DISTILLATION - Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure) causing evaporation of the most volatile liquid(s) (those with the lowest boiling points) This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure Vacuum distillation is used with or without heating the solution

Vacuum distillation increases the relative volatility of the key components in many applications The higher the relative volatility the more separable are the two components this connotes fewer stages in a distillation column in order to effect the same separation between the overhead and bottoms products Lower pressures increase relative volatilities in most systems

A second advantage of vacuum distillation is the reduced temperaturerequirement at lower pressures For many systems the products degrade or polymerize at elevated temperatures

Vacuum distillation can improve a separation by Prevention of product degradation or polymer formation

because of reduced pressure leading to lower tower bottoms temperatures

Reduction of product degradation or polymer formation because of reduced mean residence time especially in columns using packing rather than trays

Increasing capacity yield and purity

Another advantage of vacuum distillation is the reduced capital cost at the expense of slightly more operating cost Utilizing vacuum distillation can reduce the height and diameter and thus the capital cost of a distillation column

Reduced crude from main column bottom at a temperature of approx 330oC is pumped through Furnace The Furnace coil outlet (4 passes) combines in one header

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

physical and chemical properties and it is this variety that makes crude oil useful in a broad range of applications

Once separated and purified of any contaminants and impurities the fuel or lubricant can be sold without further processing Smaller molecules such as isobutane and propylene or butylenes can be recombined to meet specific octane requirements by processes such as alkylation or less commonly dimerization Octane grade of gasoline can also be improved by catalytic reforming which involves removing hydrogen from hydrocarbons producing compounds with higher octane ratings such as aromatics Intermediate products such as gasoils can even be reprocessed to break a heavy longchained oil into a lighter short-chained one by various forms of cracking such as fluid catalytic cracking thermal cracking and hydrocracking The final step in gasoline production is the blending of fuels with different octane ratings vapor pressures and other properties to meet product specifications

HIGHLIGHTS Barauni Refinery achieved highest ever crude processing

of 62 MMT (outlook) during the year Previous best was 594 MMT during the year 2008-09

Achieved highest ever Low Sulphur crude processing of 555 MMT (outlook) during the year surpassing the previous best of 516 MMT during the year 2008-09

Achieved highest ever CRU throughput of 2883 TMT (outlook) Previous best was 277 TMT during the year 1999-00

Achieved highest ever RFCCU throughput of 1497 MMT (outlook) during the year surpassing previous best of 1454 MMT during the year 2008-09

Atmospheric and Vacuum Distillation Unit (AVU-I II)

INTRODUCTION There are two Atmospheric and Vacuum Distillation Units

in Barauni Refinery numbered as AVU-I and AVU-II each were designed for 1 MMTyear crude processing Subsequently another distillation unit without vacuum distillation facility was added This unit was designed for 1 MMTyear of crude and known as AU-3 Crude Processing capacity of both units AVU-I amp AVU-II was increased to 16 MMTyear by HETO project (Heat Exchanger Train optimization) in 1990 The above modification (HETO project job was designed by EIL (Engineers India Limited) and fabricationerection job was completed by Ms PETHON ENGG LTD Mumbai The units were again revamped in 1998 (M amp I) when the capacity was expanded to 21 MMTyear of each of the two units

Through these units were designed on the basis of evaluation data of Naharkatiya crude presently the units have switched on to imported crude due to none availability of Assam crude

PROCESS DESCRIPTION Crude oil (imported) is received from Haldia by pipeline

and is pumped from tanks through Heat Exchangers after exchanging heat with various hot stream the crude streams attain a temperature of approx 120oC to 130oC

After attaining temperature about 120oC to 130oC the two crude flows combine together and enter in Desalter for separation and removal of water and salt

Bi electric desalter is having two energised electrodes A distributor head splits crude between the upper and lower pair of electrodes Crude oil separated from water between the centre and lower electrodes passes through the upper electrode in a converging countercurrent flow with the separating water from upper set of electrodes This creates a second washing zone for half of the feed in a strong electrical field thereby causing maximum salt removal efficiency The two desalter in AVU-I ampII are

PETRECO BIELECTRIC type which were commissioned in the year 2001

POST DESALTER- At the outlet of Desalter there are two booster pumps which boost up the crude at discharge pressure around 15 kgkm2 Pre-topping column has 20 Trays (All valve trays with a bed of packing between 9th

amp 10th tray) and operates operating conditions

Pretopped crude stream passes through heat exchangers

After exchanging heat with various hot products the pretopped crude flows combine and it is segregated again near furnace in two pass flows before entering the atmospheric heater for further heating and finally fed to 6th

tray of main column through two entry nozzles at 340oCThe Furnace is provided with Air Preheater

Main Fractionating Column has 43 double pass valve trays Following are the operating parameters of the main column

As per design two types of gas oil one light and other heavy were supposed to be withdrawn light gas oil from 6th

and 18th

tray and heavy gas oil from 8th10th trays at 140-300oC and 300-350oC respectively At present gas oil is withdrawn as 250-370oC cut from 16th18th

tray The existing 7th to 14th double pass

channel trays were replaced with valve trays in HETO 1990 Since 1970 heavy gas oil withdrawal was stopped Main Column bottom is feed to vacuum column

VACUUM DISTILLATION - Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure) causing evaporation of the most volatile liquid(s) (those with the lowest boiling points) This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure Vacuum distillation is used with or without heating the solution

Vacuum distillation increases the relative volatility of the key components in many applications The higher the relative volatility the more separable are the two components this connotes fewer stages in a distillation column in order to effect the same separation between the overhead and bottoms products Lower pressures increase relative volatilities in most systems

A second advantage of vacuum distillation is the reduced temperaturerequirement at lower pressures For many systems the products degrade or polymerize at elevated temperatures

Vacuum distillation can improve a separation by Prevention of product degradation or polymer formation

because of reduced pressure leading to lower tower bottoms temperatures

Reduction of product degradation or polymer formation because of reduced mean residence time especially in columns using packing rather than trays

Increasing capacity yield and purity

Another advantage of vacuum distillation is the reduced capital cost at the expense of slightly more operating cost Utilizing vacuum distillation can reduce the height and diameter and thus the capital cost of a distillation column

Reduced crude from main column bottom at a temperature of approx 330oC is pumped through Furnace The Furnace coil outlet (4 passes) combines in one header

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

HIGHLIGHTS Barauni Refinery achieved highest ever crude processing

of 62 MMT (outlook) during the year Previous best was 594 MMT during the year 2008-09

Achieved highest ever Low Sulphur crude processing of 555 MMT (outlook) during the year surpassing the previous best of 516 MMT during the year 2008-09

Achieved highest ever CRU throughput of 2883 TMT (outlook) Previous best was 277 TMT during the year 1999-00

Achieved highest ever RFCCU throughput of 1497 MMT (outlook) during the year surpassing previous best of 1454 MMT during the year 2008-09

Atmospheric and Vacuum Distillation Unit (AVU-I II)

INTRODUCTION There are two Atmospheric and Vacuum Distillation Units

in Barauni Refinery numbered as AVU-I and AVU-II each were designed for 1 MMTyear crude processing Subsequently another distillation unit without vacuum distillation facility was added This unit was designed for 1 MMTyear of crude and known as AU-3 Crude Processing capacity of both units AVU-I amp AVU-II was increased to 16 MMTyear by HETO project (Heat Exchanger Train optimization) in 1990 The above modification (HETO project job was designed by EIL (Engineers India Limited) and fabricationerection job was completed by Ms PETHON ENGG LTD Mumbai The units were again revamped in 1998 (M amp I) when the capacity was expanded to 21 MMTyear of each of the two units

Through these units were designed on the basis of evaluation data of Naharkatiya crude presently the units have switched on to imported crude due to none availability of Assam crude

PROCESS DESCRIPTION Crude oil (imported) is received from Haldia by pipeline

and is pumped from tanks through Heat Exchangers after exchanging heat with various hot stream the crude streams attain a temperature of approx 120oC to 130oC

After attaining temperature about 120oC to 130oC the two crude flows combine together and enter in Desalter for separation and removal of water and salt

Bi electric desalter is having two energised electrodes A distributor head splits crude between the upper and lower pair of electrodes Crude oil separated from water between the centre and lower electrodes passes through the upper electrode in a converging countercurrent flow with the separating water from upper set of electrodes This creates a second washing zone for half of the feed in a strong electrical field thereby causing maximum salt removal efficiency The two desalter in AVU-I ampII are

PETRECO BIELECTRIC type which were commissioned in the year 2001

POST DESALTER- At the outlet of Desalter there are two booster pumps which boost up the crude at discharge pressure around 15 kgkm2 Pre-topping column has 20 Trays (All valve trays with a bed of packing between 9th

amp 10th tray) and operates operating conditions

Pretopped crude stream passes through heat exchangers

After exchanging heat with various hot products the pretopped crude flows combine and it is segregated again near furnace in two pass flows before entering the atmospheric heater for further heating and finally fed to 6th

tray of main column through two entry nozzles at 340oCThe Furnace is provided with Air Preheater

Main Fractionating Column has 43 double pass valve trays Following are the operating parameters of the main column

As per design two types of gas oil one light and other heavy were supposed to be withdrawn light gas oil from 6th

and 18th

tray and heavy gas oil from 8th10th trays at 140-300oC and 300-350oC respectively At present gas oil is withdrawn as 250-370oC cut from 16th18th

tray The existing 7th to 14th double pass

channel trays were replaced with valve trays in HETO 1990 Since 1970 heavy gas oil withdrawal was stopped Main Column bottom is feed to vacuum column

VACUUM DISTILLATION - Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure) causing evaporation of the most volatile liquid(s) (those with the lowest boiling points) This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure Vacuum distillation is used with or without heating the solution

Vacuum distillation increases the relative volatility of the key components in many applications The higher the relative volatility the more separable are the two components this connotes fewer stages in a distillation column in order to effect the same separation between the overhead and bottoms products Lower pressures increase relative volatilities in most systems

A second advantage of vacuum distillation is the reduced temperaturerequirement at lower pressures For many systems the products degrade or polymerize at elevated temperatures

Vacuum distillation can improve a separation by Prevention of product degradation or polymer formation

because of reduced pressure leading to lower tower bottoms temperatures

Reduction of product degradation or polymer formation because of reduced mean residence time especially in columns using packing rather than trays

Increasing capacity yield and purity

Another advantage of vacuum distillation is the reduced capital cost at the expense of slightly more operating cost Utilizing vacuum distillation can reduce the height and diameter and thus the capital cost of a distillation column

Reduced crude from main column bottom at a temperature of approx 330oC is pumped through Furnace The Furnace coil outlet (4 passes) combines in one header

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Achieved highest ever RFCCU throughput of 1497 MMT (outlook) during the year surpassing previous best of 1454 MMT during the year 2008-09

Atmospheric and Vacuum Distillation Unit (AVU-I II)

INTRODUCTION There are two Atmospheric and Vacuum Distillation Units

in Barauni Refinery numbered as AVU-I and AVU-II each were designed for 1 MMTyear crude processing Subsequently another distillation unit without vacuum distillation facility was added This unit was designed for 1 MMTyear of crude and known as AU-3 Crude Processing capacity of both units AVU-I amp AVU-II was increased to 16 MMTyear by HETO project (Heat Exchanger Train optimization) in 1990 The above modification (HETO project job was designed by EIL (Engineers India Limited) and fabricationerection job was completed by Ms PETHON ENGG LTD Mumbai The units were again revamped in 1998 (M amp I) when the capacity was expanded to 21 MMTyear of each of the two units

Through these units were designed on the basis of evaluation data of Naharkatiya crude presently the units have switched on to imported crude due to none availability of Assam crude

PROCESS DESCRIPTION Crude oil (imported) is received from Haldia by pipeline

and is pumped from tanks through Heat Exchangers after exchanging heat with various hot stream the crude streams attain a temperature of approx 120oC to 130oC

After attaining temperature about 120oC to 130oC the two crude flows combine together and enter in Desalter for separation and removal of water and salt

Bi electric desalter is having two energised electrodes A distributor head splits crude between the upper and lower pair of electrodes Crude oil separated from water between the centre and lower electrodes passes through the upper electrode in a converging countercurrent flow with the separating water from upper set of electrodes This creates a second washing zone for half of the feed in a strong electrical field thereby causing maximum salt removal efficiency The two desalter in AVU-I ampII are

PETRECO BIELECTRIC type which were commissioned in the year 2001

POST DESALTER- At the outlet of Desalter there are two booster pumps which boost up the crude at discharge pressure around 15 kgkm2 Pre-topping column has 20 Trays (All valve trays with a bed of packing between 9th

amp 10th tray) and operates operating conditions

Pretopped crude stream passes through heat exchangers

After exchanging heat with various hot products the pretopped crude flows combine and it is segregated again near furnace in two pass flows before entering the atmospheric heater for further heating and finally fed to 6th

tray of main column through two entry nozzles at 340oCThe Furnace is provided with Air Preheater

Main Fractionating Column has 43 double pass valve trays Following are the operating parameters of the main column

As per design two types of gas oil one light and other heavy were supposed to be withdrawn light gas oil from 6th

and 18th

tray and heavy gas oil from 8th10th trays at 140-300oC and 300-350oC respectively At present gas oil is withdrawn as 250-370oC cut from 16th18th

tray The existing 7th to 14th double pass

channel trays were replaced with valve trays in HETO 1990 Since 1970 heavy gas oil withdrawal was stopped Main Column bottom is feed to vacuum column

VACUUM DISTILLATION - Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure) causing evaporation of the most volatile liquid(s) (those with the lowest boiling points) This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure Vacuum distillation is used with or without heating the solution

Vacuum distillation increases the relative volatility of the key components in many applications The higher the relative volatility the more separable are the two components this connotes fewer stages in a distillation column in order to effect the same separation between the overhead and bottoms products Lower pressures increase relative volatilities in most systems

A second advantage of vacuum distillation is the reduced temperaturerequirement at lower pressures For many systems the products degrade or polymerize at elevated temperatures

Vacuum distillation can improve a separation by Prevention of product degradation or polymer formation

because of reduced pressure leading to lower tower bottoms temperatures

Reduction of product degradation or polymer formation because of reduced mean residence time especially in columns using packing rather than trays

Increasing capacity yield and purity

Another advantage of vacuum distillation is the reduced capital cost at the expense of slightly more operating cost Utilizing vacuum distillation can reduce the height and diameter and thus the capital cost of a distillation column

Reduced crude from main column bottom at a temperature of approx 330oC is pumped through Furnace The Furnace coil outlet (4 passes) combines in one header

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

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DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Atmospheric and Vacuum Distillation Unit (AVU-I II)

INTRODUCTION There are two Atmospheric and Vacuum Distillation Units

in Barauni Refinery numbered as AVU-I and AVU-II each were designed for 1 MMTyear crude processing Subsequently another distillation unit without vacuum distillation facility was added This unit was designed for 1 MMTyear of crude and known as AU-3 Crude Processing capacity of both units AVU-I amp AVU-II was increased to 16 MMTyear by HETO project (Heat Exchanger Train optimization) in 1990 The above modification (HETO project job was designed by EIL (Engineers India Limited) and fabricationerection job was completed by Ms PETHON ENGG LTD Mumbai The units were again revamped in 1998 (M amp I) when the capacity was expanded to 21 MMTyear of each of the two units

Through these units were designed on the basis of evaluation data of Naharkatiya crude presently the units have switched on to imported crude due to none availability of Assam crude

PROCESS DESCRIPTION Crude oil (imported) is received from Haldia by pipeline

and is pumped from tanks through Heat Exchangers after exchanging heat with various hot stream the crude streams attain a temperature of approx 120oC to 130oC

After attaining temperature about 120oC to 130oC the two crude flows combine together and enter in Desalter for separation and removal of water and salt

Bi electric desalter is having two energised electrodes A distributor head splits crude between the upper and lower pair of electrodes Crude oil separated from water between the centre and lower electrodes passes through the upper electrode in a converging countercurrent flow with the separating water from upper set of electrodes This creates a second washing zone for half of the feed in a strong electrical field thereby causing maximum salt removal efficiency The two desalter in AVU-I ampII are

PETRECO BIELECTRIC type which were commissioned in the year 2001

POST DESALTER- At the outlet of Desalter there are two booster pumps which boost up the crude at discharge pressure around 15 kgkm2 Pre-topping column has 20 Trays (All valve trays with a bed of packing between 9th

amp 10th tray) and operates operating conditions

Pretopped crude stream passes through heat exchangers

After exchanging heat with various hot products the pretopped crude flows combine and it is segregated again near furnace in two pass flows before entering the atmospheric heater for further heating and finally fed to 6th

tray of main column through two entry nozzles at 340oCThe Furnace is provided with Air Preheater

Main Fractionating Column has 43 double pass valve trays Following are the operating parameters of the main column

As per design two types of gas oil one light and other heavy were supposed to be withdrawn light gas oil from 6th

and 18th

tray and heavy gas oil from 8th10th trays at 140-300oC and 300-350oC respectively At present gas oil is withdrawn as 250-370oC cut from 16th18th

tray The existing 7th to 14th double pass

channel trays were replaced with valve trays in HETO 1990 Since 1970 heavy gas oil withdrawal was stopped Main Column bottom is feed to vacuum column

VACUUM DISTILLATION - Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure) causing evaporation of the most volatile liquid(s) (those with the lowest boiling points) This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure Vacuum distillation is used with or without heating the solution

Vacuum distillation increases the relative volatility of the key components in many applications The higher the relative volatility the more separable are the two components this connotes fewer stages in a distillation column in order to effect the same separation between the overhead and bottoms products Lower pressures increase relative volatilities in most systems

A second advantage of vacuum distillation is the reduced temperaturerequirement at lower pressures For many systems the products degrade or polymerize at elevated temperatures

Vacuum distillation can improve a separation by Prevention of product degradation or polymer formation

because of reduced pressure leading to lower tower bottoms temperatures

Reduction of product degradation or polymer formation because of reduced mean residence time especially in columns using packing rather than trays

Increasing capacity yield and purity

Another advantage of vacuum distillation is the reduced capital cost at the expense of slightly more operating cost Utilizing vacuum distillation can reduce the height and diameter and thus the capital cost of a distillation column

Reduced crude from main column bottom at a temperature of approx 330oC is pumped through Furnace The Furnace coil outlet (4 passes) combines in one header

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

PETRECO BIELECTRIC type which were commissioned in the year 2001

POST DESALTER- At the outlet of Desalter there are two booster pumps which boost up the crude at discharge pressure around 15 kgkm2 Pre-topping column has 20 Trays (All valve trays with a bed of packing between 9th

amp 10th tray) and operates operating conditions

Pretopped crude stream passes through heat exchangers

After exchanging heat with various hot products the pretopped crude flows combine and it is segregated again near furnace in two pass flows before entering the atmospheric heater for further heating and finally fed to 6th

tray of main column through two entry nozzles at 340oCThe Furnace is provided with Air Preheater

Main Fractionating Column has 43 double pass valve trays Following are the operating parameters of the main column

As per design two types of gas oil one light and other heavy were supposed to be withdrawn light gas oil from 6th

and 18th

tray and heavy gas oil from 8th10th trays at 140-300oC and 300-350oC respectively At present gas oil is withdrawn as 250-370oC cut from 16th18th

tray The existing 7th to 14th double pass

channel trays were replaced with valve trays in HETO 1990 Since 1970 heavy gas oil withdrawal was stopped Main Column bottom is feed to vacuum column

VACUUM DISTILLATION - Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure) causing evaporation of the most volatile liquid(s) (those with the lowest boiling points) This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure Vacuum distillation is used with or without heating the solution

Vacuum distillation increases the relative volatility of the key components in many applications The higher the relative volatility the more separable are the two components this connotes fewer stages in a distillation column in order to effect the same separation between the overhead and bottoms products Lower pressures increase relative volatilities in most systems

A second advantage of vacuum distillation is the reduced temperaturerequirement at lower pressures For many systems the products degrade or polymerize at elevated temperatures

Vacuum distillation can improve a separation by Prevention of product degradation or polymer formation

because of reduced pressure leading to lower tower bottoms temperatures

Reduction of product degradation or polymer formation because of reduced mean residence time especially in columns using packing rather than trays

Increasing capacity yield and purity

Another advantage of vacuum distillation is the reduced capital cost at the expense of slightly more operating cost Utilizing vacuum distillation can reduce the height and diameter and thus the capital cost of a distillation column

Reduced crude from main column bottom at a temperature of approx 330oC is pumped through Furnace The Furnace coil outlet (4 passes) combines in one header

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

channel trays were replaced with valve trays in HETO 1990 Since 1970 heavy gas oil withdrawal was stopped Main Column bottom is feed to vacuum column

VACUUM DISTILLATION - Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure) causing evaporation of the most volatile liquid(s) (those with the lowest boiling points) This distillation method works on the principle that boiling occurs when the vapor pressure of a liquid exceeds the ambient pressure Vacuum distillation is used with or without heating the solution

Vacuum distillation increases the relative volatility of the key components in many applications The higher the relative volatility the more separable are the two components this connotes fewer stages in a distillation column in order to effect the same separation between the overhead and bottoms products Lower pressures increase relative volatilities in most systems

A second advantage of vacuum distillation is the reduced temperaturerequirement at lower pressures For many systems the products degrade or polymerize at elevated temperatures

Vacuum distillation can improve a separation by Prevention of product degradation or polymer formation

because of reduced pressure leading to lower tower bottoms temperatures

Reduction of product degradation or polymer formation because of reduced mean residence time especially in columns using packing rather than trays

Increasing capacity yield and purity

Another advantage of vacuum distillation is the reduced capital cost at the expense of slightly more operating cost Utilizing vacuum distillation can reduce the height and diameter and thus the capital cost of a distillation column

Reduced crude from main column bottom at a temperature of approx 330oC is pumped through Furnace The Furnace coil outlet (4 passes) combines in one header

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

and enter into vacuum column at 4th plates through two entry nozzle Coil outlet temperature is maintained at about 380oC Operating condition of Vacuum Column are as follows

STABILIZER COLUMN-Unstabilised gasoline is pumped to 16th2024th tray of Stabiliser Feed temperature is about 110oc The column has 35 valve trays Operating conditions of Stabiliser are-

LPG CAUSTIC WASHLPG caustic wash facilities were provided in AVU-II and was first commissioned in Sept1984 where LPG of AVUndashI AVU-II is washed with caustic solution of 10-12 strength

Heavy Naphtha is drawn from main column 36th tray through stripper

Operating parameters

Product Streams Ex AVU-III

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

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nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

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r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

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s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

TEMPERED WATER FACILITIES (HETO - 1990)

During HETO tempered water facility was provided in AVU-2 Tempered water is used as cooling media in SR cooler instead of Pressurised cooling water as is being used in conventional coolers This facility is common for both AVU-1 amp AVU-2 Tempered water is steam condensate received from condensate recovery system of refinery with neutral ph value after chemical treatment Use of tempered water in cooler prevents the sealing and corrosion in cooler tubes thus ensuring the very efficient cooling of product (SR) and minimising to a great extent the maint of the cooler Tempered water facility is essentially a closed circulating system in which the loss of tempered water during circulation is very negligible

CORROSION CONTROL- Ammonia is injected in the form of aquous solution for preventing HCL corrosion in pretopping and main column overheads Recent modification of this system is the installation of on line pH meters for measuring pH in both the units

AHURALAN INJECTION- Ahuralan is the trade name of an organic inhibitor compound used for preventing corrosion of condenser shell It prevents corrosion by

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

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ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

forming a thin protective layer on the equipment A 5 WV and 2 WV solutions are prepared in AVU-I and AVU-II respectively Injection rate in both the units is 5 PPM of overhead contents

MAJOR EQUIPMENT

TUBULAR FURNACES Tubular furnace is cylindrical type for pretopping and

vacuum sections It is box type for the main distillation column

The furnaces have sections called Radiation Section and convection section A part of the tube in convection zone is for super-heating steam( used in the process) and the rest is used for heating the oil in tubes

The inside walls of the furnace are protected against the temperature effects by a refractory insulation to reduce the outside heat losses

The bottom bed show openings in which burners are placed The flue gases go out of the furnace thorough the stack

The stack is protected inside in its lower part where the flue gases are still very hot by a wall of refractory bricks A damper is located at its base to allow the regulation of the draft This damper is built with steel suitable for the flues gases temperature

BURNERS The burner is conceived to burn either gas or oil Gas

burners are of two types either with pre-mixing or without premixing In the first type a part of the combustion air is mixed with the fuel gas before this has reached the injector nozzle of the burner The burners without premixing give a diffusion flame the combustion air entering the furnace in a parallel direction with the gas jet and slowly diffusing in it AVUs gas burners are of this type They give a longer and more luminous flame than those with premixing

AVUs burners are of inside-mix type In these the steam and oil are mixed in a chamber within the burners and they issue together from the burner as a single stream Foam formed in the mixing chamber is directed by the

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

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withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

shape and direction of the burner tip so that the flame is of proper shape and size for the furnace boxThe burners with spraying by steam have a flexibility much higher than those with mechanical spraying

Atmospheric and Vacuum Distillation Unit III

The Process

Crude preheat o Crude is pumped to desalter through two parallel

passes in Pre- Desalter Heat Exchanger Train-1o The first pass consists of four nos of heat

exchangerso The second pass of heat exchangers also has four

nos of heat exchangers

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

o Both the passes combine in a single header and enter the desalter

Desalter circuit-A static Mix valve and a control valve is provided for mixing water and demulsifier with crude prior to entry into the desalter The desalter pressure is controlled at around 90 Kgcm2 (g) The desalted crude is pumped to Pretopping Column

Heat exchanger train ii-The discharge is through a series of heat exchangers (6 Nos) In this network of heat exchangers crude is heated by outgoing products to a temperature of around 230 degC

Pretopping column- The desalted crude at 230ordmC enters the columns for withdrawal of unstabilised gasoline and heavy naptha

Heat exchanger train iii- The bottom product at a temperature of around 250 degC is pumped to furnace through heat exchangers and then after combining is routed in parallel streams through pre-heat exchangers (3 Nos) The preheat temperature at the exit is around 270 degC Part of the bottom product coming out of the heat exchanger train is sent to Pretopping Column as heat input The coil outlet temperature of the furnace is maintained at around 360 degC Pre topping column bottom product is sent through the main furnace The coil outlet temperature is maintained at around 360degC

Main fractionator-The main column is provided with Valve trays in the top section KERO LGO section Structured packing in LGO HGO section The bottom stripping section and Over-flash section The column bottoms (RCO) is flashed into the Vacuum Column Stabiliser section-Part of the condensed overhead gasoline is pumpedthrough heat exchanger to stabiliser section Lpg caustics wash-LPG goes to LPG caustic wash-vessel after mixing withcaustic Vacuum section The Vacuum column is provided with structured packing in LVGO

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

pumparound section LVGOHVGO fractionation section HVGOpumparound section and Wash section and valve trays in the bottomsstripping section The column is operated at a top pressure of 70 mmHg K-301 top is provided with a demister to minimize the entertainment ofliquid droplets in the vapour going to overhead-condenser The side streams of main vacuum column are as under Stream ProductFirst LVGO amp CRSecond HVGO amp CRThird SLOP amp OVERFLASHBottom SHORT RESIDUE This Reboiler Furnace is a vertical cylindrical heater with convectionand radiant section The heater houses 12 nos of horizontal tubes in convection section and48 nos bare tubes 6 NB of A335 P9 material These 48 tubes arearranged in double pass arrangement giving material total radiant heattransfer area of 2488 m2 The firing of this heater is done by 4 noscombination fuel fired forced draft burners provided with pilotburners having automatic electric ignition system Refractory materialused in the radiant sanction of this heater is ceramic fiber blanket Crude heater is a vertical cylindrical heater with convection andradiant sections The radiant section of the heater houses 88 nos bare tubes of 6 NBof A335 P9 material These 88 tubes are arranged in four-passarrangement giving total heat transfer area of 8568 M2 In the horizontal convection section there are 24 nos bare tubes ofA335 P9 material and 64 nos of studded tubes with an extended

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

surface area of 950 M2 In the convection section there are also 12nos of extended surface tubes for steam superheat with an extendedsurface area of 70 M2 The firing of this heater is done by 8 nos combined fuel fired forceddraft burners provided with pilot burners having automatic electricignition system Refraction material used in the radiant section of thisheater is ceramic fiber blanket Vacuum heater F-301 is a vertical cylindrical heater with convectionand radiant section In each pass of the furnace there is arrangement for introducingturbulising steam at convection section inlet and convection sectionoutlet The radiant section of the heater houses 54 nos bare tube of 6 eachNB A335 P9 material These tubes are arranged in two parallel passesgiving total heat transfer area of 330 M2 In the convection section there are 12 nos of bare tubes of A335 P9material of total surface area of 3481 M2 amp 44 nos of studded tubesof A335 P9 material of total exposed surface area of 509 M2 The firing of this heater is done by 4 nos of combined fuel firedforced draft burners provided at the floor with pilot burners havingautomatic electric ignition system Refractory material used in theradiant section is ceramic fiber blanket Air preheater -During normal operation combustion air for all furnacesis supplied by forced draft fans Air is preheated at 236oC in a commonair pre-heater

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Air preheating is based on heat exchange between hot flue gas andcombustion air Hot flue gas leaving the convection section of thefurnaces at 323oC is mixed together before going to shell side of theAPH (annular spaces between the finned modules) The cast iron HTHTA tubes have integral fins on the inside (air) andoutside (flue gas) surfaces Air preheater is provided with glass tubes in the lowest pass in order toavoid corrosion due to acid condensation in cold flue gases

LPG RECOVERY UNIT ( LRU )CAPACITY STREAM FACTORi)Gas and unstabilised naphtha from ACU 99000 Tonnes Yearii)Gas from existing Coker Unit 93696 iii)Stream factor 320 daysiv)Unit Turndown 25v)Year of Commissioning 1986INTRODUCTIONGases from Coker-A Coker-B amp Stabiliser off-gas from AVU-I II IIIare compressed in a two stage steam turbine driven compressor Compressedgases at a pressure of 140Kgcmsup2g along with unstabilised naphtha arecooled to 40degC in air and water cooler successively and fed to a dischargeknock-out pot where gas and condensate (mainly-LPG) are separatedGases from the knock-out pot are passed through an absorber column andflow counter to the naphtha and kerosene streams in two separate sectionsrespectively Naphtha absorbs any C3C4 fractions present in the gasKerosene further minimises the loss of naphtha entrained by the gasesKerosene is taken from cikers and rich kerosene from this absorber is fedback to the fractionating column of cokers Rich naphtha from the lower

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

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ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

zone of the absorber along with the condensate obtained from thecompressor discharge knock-out drum is preheated by Debutaniser bottomstream and pumped to stripper column where light ends ( C1 and C2 ) arestripped off by reboiler vapour and fed back to the inlet of compressordischarge KO drum ( to recover C3 C4 if any)Fuel gas from the absorber top goes to a knock-out drum and fed to therefinery gas network Stripper bottom containing mainly LPG and Naphthaare fed to the Debutaniser column for separation of LPG and Naphtha LPGis withdrawn from the top reflux drum and stabilised naphtha from thebottom of the debutaniser column A required part of this stabilised naphthais recycled back to the absorber as absorbing medium and rest of stabilisednaphtha goes as productBoth LPG and stabilised naphtha products are further washed in caustic sodawash section separately for removal of any H2SProducts are further passed through sand filters and then sent to theproduct storage tanksFEED - STOCKa) Gas from ACU c) Gases from existing CokerCOMPONENT WT Methane 257EthaneEthylene 189Propane 177Propylene 86i-Butane 1b) Unstabilised naphtha from ACUSp Gravity at 15degC - 0710Vap Pressure 220 Kgcmsup2gPRODUCT CHARACTERISTICSLPGCopper strip corrosion for1 hr at 38degC1b Max

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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uces verr of theer byprotanesesence oupon tsired reres of aormingh are veTherefoprocessnd the nng reacthenesthylcyc

EFORss usedoctane romponecess reha feedcules Tns withthe hyarates hry signie otheroductsof a cathe typeeactionabout 4catalysery susre thesed in anitrogenctions ato convclohexan

RMINd to conratingsents ofe-arrangdstocksThe oveh more cydrocarhydrogeficant aprocessare smatalyst ae or verseverit495 to 5sts consceptibnaphthhydron compoare-vert thene (a na

NG UNnvert pe into hihigh-ocges or ras welerall effcomplexbons inen atomamountses invoall amouand a hirsion ofty the

525 degCtain noble to poha feeddesulfuoundsem intoaphthen

NIT)etroleumigh-octctane gare-strul as brefect is tx molecthe nams froms of byolved inunts ofgh partf catalyreactioand froble metoisoningdstock turizatioaromatne) to tmane liquasolineuctureseakingthat thcularphtham theyproducn a

ftialticonomtals sucg byto aon unittics astolueneuidhetch-2 Thethe coshown3 The(commnorma4 Thethe crThe hreforparafdehydprodureforof hydfeedsTypicThe onapht(petrohydroreforwith adifferdegC ande isome

onversin belowe dehydmonly caal heptae hydrorackinghydrocrming refins dodrogenauce hydrming ofdrogenstockal naphoverheatha andol) prododesulfumer tohigherrent hyd a finaerizatioon of ndrogenaalled deane to tocrackinof norrackingeactionses not cation ofrogen Tf petrolgas (aththa fead liquidwill bec

duct afturizer treformr octanydrocaral boilingon of noormal oation aehydroctolueneng of pmal hepof paras that cconsumf naphthThe oveleum nat 0 degC aeedstocd distillacome ater it isto remom its hye ratingbon comg pointormal poctane tnd aromcyclizat as shoparaffinptane inaffins isconsumeme or prhenes aerall neaphthas

nd 1 atmcksate fromajors furtheove sulfydrocarbg valuempoundof aboparaffinto 25-Dmatizattion) asown belons intonto isops the ones hydrroduce hand theet produs rangesm) perm atmocomponer procfur-contbon mo The nas It haut 200ns to isDimethytion ofexempowsmallerpentanenly onerogen Thydroge

dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Dryness enrained water No freeCOMPONENT WT Methane 2628Ethane 1528Ethylene 417Propylene 929i-Butane 2400n-Butane 768C is-TransButane856C5 1112H2S AbsentOdor (Min) Level 2Total Volatile Solution (Max) 002WT (95 Vaporised at 760 mm Hg (Max) + 2degCVapour pressure at 65degC Kgcmsup2g 15 MaxSTABILISED NAPHTHATBP C5 + 140degC15degC 07109HYDROCARBON WT- Saturates 645- Olefins 235- Aromatics 120Mercaptans wt 0016Cu Strip corrosionBut (3hrs at 50degC) 2aRVP psig (max) 100FUEL GAS WT Methane 4523Ethylene 720Ethane 2550Propylene 760Propane 1170C5 + 277BATTERY LIMIT CONDITIONSFEED PRODUCTS Kgcmsup2g 0degC DESTINATION SOURCEGas 22 45 ACUexistingUnstabilisedNaphtha165 45 ACUFuel Gas 20 50 Refinery FG systemLPG 203 40 LPG StorageStabilised Naphtha 50 40 NaphthaMS TanksMATERIAL BALANCESNo COMPONENT FEEDTYRPRODUCTTYR

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

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ftialticonomtals sucg byto aon unittics astolueneuidhetch-2 Thethe coshown3 The(commnorma4 Thethe crThe hreforparafdehydprodureforof hydfeedsTypicThe onapht(petrohydroreforwith adifferdegC ande isome

onversin belowe dehydmonly caal heptae hydrorackinghydrocrming refins dodrogenauce hydrming ofdrogenstockal naphoverheatha andol) prododesulfumer tohigherrent hyd a finaerizatioon of ndrogenaalled deane to tocrackinof norrackingeactionses not cation ofrogen Tf petrolgas (aththa fead liquidwill bec

duct afturizer treformr octanydrocaral boilingon of noormal oation aehydroctolueneng of pmal hepof paras that cconsumf naphthThe oveleum nat 0 degC aeedstocd distillacome ater it isto remom its hye ratingbon comg pointormal poctane tnd aromcyclizat as shoparaffinptane inaffins isconsumeme or prhenes aerall neaphthas

nd 1 atmcksate fromajors furtheove sulfydrocarbg valuempoundof aboparaffinto 25-Dmatizattion) asown belons intonto isops the ones hydrroduce hand theet produs rangesm) perm atmocomponer procfur-contbon mo The nas It haut 200ns to isDimethytion ofexempowsmallerpentanenly onerogen Thydroge

dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

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ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

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hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

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r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

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s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

DESTINATION1 Gas 92660 Existing FG System2 LPG 192696 52016 LPG Storage3 Naphtha 57220 NaphthaMS TankUTILITIES CONSUMPTIONUTILITY PRESSURE TEMP 0degC CONSUMPTIONKgcmsup2gHigh Pressure Steam(SH) 34 415 25000 KghrMedium pressure Steam 190 211 9594 KghrLow pressure steam (SL) 25 290 Intermittent LostStation Cooling water (WC) 25 693 Msup3hrInst Air 35 40 60 NMsup3hrPlant Air 65 40 340 NMsup3hr Fresh water 70 Ambient 6 Intermittent If ACU is down consumption shall be 347Msup3hrCHEMICALSCaustic soda 120 tonesYearCorrosion inhibitor 075 tonesYearCatalyrefineprodu(also kthe hysomeprodushapefeedshydrohydromodermethaThe rAll thpressreforconditpressThe cas plasulfurcatalywhich

The f1 Theexemp

Cytic reery napucts calknown aydrocarof theuct refoes havinstock Iocarbonogen gasrn petrane ethreactionhe reacture ofming ustions raures ofcommonatinum ar and niytic refh removfour maje dehydplified

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CATAg is a chtypicallormateol) Basoleculesules intocontainer octanoing theules andse in a nrefineryropanemistryccur in ten Depwell as tom tem5 to 45catalytrheniumcompouis alway

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ALYTIhemically havines whichsically ts in theo smallens hydrne valuee proced produnumbery Otheand butthe prependingthe desmperatu5 atmtic refom whichunds Tys preulfuranreformif naphtsion met

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EFORss usedoctane romponecess reha feedcules Tns withthe hyarates hry signie otheroductsof a cathe typeeactionabout 4catalysery susre thesed in anitrogenctions ato convclohexan

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NG UNnvert pe into hihigh-ocges or ras welerall effcomplexbons inen atomamountses invoall amouand a hirsion ofty the

525 degCtain noble to poha feeddesulfuoundsem intoaphthen

NIT)etroleumigh-octctane gare-strul as brefect is tx molecthe nams froms of byolved inunts ofgh partf catalyreactioand froble metoisoningdstock turizatioaromatne) to tmane liquasolineuctureseakingthat thcularphtham theyproducn a

ftialticonomtals sucg byto aon unittics astolueneuidhetch-2 Thethe coshown3 The(commnorma4 Thethe crThe hreforparafdehydprodureforof hydfeedsTypicThe onapht(petrohydroreforwith adifferdegC ande isome

onversin belowe dehydmonly caal heptae hydrorackinghydrocrming refins dodrogenauce hydrming ofdrogenstockal naphoverheatha andol) prododesulfumer tohigherrent hyd a finaerizatioon of ndrogenaalled deane to tocrackinof norrackingeactionses not cation ofrogen Tf petrolgas (aththa fead liquidwill bec

duct afturizer treformr octanydrocaral boilingon of noormal oation aehydroctolueneng of pmal hepof paras that cconsumf naphthThe oveleum nat 0 degC aeedstocd distillacome ater it isto remom its hye ratingbon comg pointormal poctane tnd aromcyclizat as shoparaffinptane inaffins isconsumeme or prhenes aerall neaphthas

nd 1 atmcksate fromajors furtheove sulfydrocarbg valuempoundof aboparaffinto 25-Dmatizattion) asown belons intonto isops the ones hydrroduce hand theet produs rangesm) perm atmocomponer procfur-contbon mo The nas It haut 200ns to isDimethytion ofexempowsmallerpentanenly onerogen Thydroge

dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

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hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

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ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

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zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

n molecus for usoleum rhane prn chemtions ochydrogsed as wange frof aboutly usedandortrogenformeres bothjor catadrogenain the c

CATAg is a chtypicallormateol) Basoleculesules intocontainer octanoing theules andse in a nrefineryropanemistryccur in ten Depwell as tom tem5 to 45catalytrheniumcompouis alway

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onversin belowe dehydmonly caal heptae hydrorackinghydrocrming refins dodrogenauce hydrming ofdrogenstockal naphoverheatha andol) prododesulfumer tohigherrent hyd a finaerizatioon of ndrogenaalled deane to tocrackinof norrackingeactionses not cation ofrogen Tf petrolgas (aththa fead liquidwill bec

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nd 1 atmcksate fromajors furtheove sulfydrocarbg valuempoundof aboparaffinto 25-Dmatizattion) asown belons intonto isops the ones hydrroduce hand theet produs rangesm) perm atmocomponer procfur-contbon mo The nas It haut 200ns to isDimethytion ofexempowsmallerpentanenly onerogen Thydroge

dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

h the sualytic ration ofconvers

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zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

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or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

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ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

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965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

525 degCtain noble to poha feeddesulfuoundsem intoaphthen

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zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

ftialticonomtals sucg byto aon unittics astolueneuidhetch-2 Thethe coshown3 The(commnorma4 Thethe crThe hreforparafdehydprodureforof hydfeedsTypicThe onapht(petrohydroreforwith adifferdegC ande isome

onversin belowe dehydmonly caal heptae hydrorackinghydrocrming refins dodrogenauce hydrming ofdrogenstockal naphoverheatha andol) prododesulfumer tohigherrent hyd a finaerizatioon of ndrogenaalled deane to tocrackinof norrackingeactionses not cation ofrogen Tf petrolgas (aththa fead liquidwill bec

duct afturizer treformr octanydrocaral boilingon of noormal oation aehydroctolueneng of pmal hepof paras that cconsumf naphthThe oveleum nat 0 degC aeedstocd distillacome ater it isto remom its hye ratingbon comg pointormal poctane tnd aromcyclizat as shoparaffinptane inaffins isconsumeme or prhenes aerall neaphthas

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dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

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MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

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T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

onversin belowe dehydmonly caal heptae hydrorackinghydrocrming refins dodrogenauce hydrming ofdrogenstockal naphoverheatha andol) prododesulfumer tohigherrent hyd a finaerizatioon of ndrogenaalled deane to tocrackinof norrackingeactionses not cation ofrogen Tf petrolgas (aththa fead liquidwill bec

duct afturizer treformr octanydrocaral boilingon of noormal oation aehydroctolueneng of pmal hepof paras that cconsumf naphthThe oveleum nat 0 degC aeedstocd distillacome ater it isto remom its hye ratingbon comg pointormal poctane tnd aromcyclizat as shoparaffinptane inaffins isconsumeme or prhenes aerall neaphthas

nd 1 atmcksate fromajors furtheove sulfydrocarbg valuempoundof aboparaffinto 25-Dmatizattion) asown belons intonto isops the ones hydrroduce hand theet produs rangesm) perm atmocomponer procfur-contbon mo The nas It haut 200ns to isDimethytion ofexempowsmallerpentanenly onerogen Thydroge

dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

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T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

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kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

duct afturizer treformr octanydrocaral boilingon of noormal oation aehydroctolueneng of pmal hepof paras that cconsumf naphthThe oveleum nat 0 degC aeedstocd distillacome ater it isto remom its hye ratingbon comg pointormal poctane tnd aromcyclizat as shoparaffinptane inaffins isconsumeme or prhenes aerall neaphthas

nd 1 atmcksate fromajors furtheove sulfydrocarbg valuempoundof aboparaffinto 25-Dmatizattion) asown belons intonto isops the ones hydrroduce hand theet produs rangesm) perm atmocomponer procfur-contbon mo The nas It haut 200ns to isDimethytion ofexempowsmallerpentanenly onerogen Thydroge

dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

nd 1 atmcksate fromajors furtheove sulfydrocarbg valuempoundof aboparaffinto 25-Dmatizattion) asown belons intonto isops the ones hydrroduce hand theet produs rangesm) perm atmocomponer procfur-contbon mo The nas It haut 200ns to isDimethytion ofexempowsmallerpentanenly onerogen Thydroge

dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

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or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

dehydruction os from acubic mosphericnent ofcessed ttainingleculesaphthaas an indegC andsoparafylhexanparaffplified inr molece and etof theThe isomen Howrocyclizof hydroabout 5meter ofc distillthe refthroughhydrocinto mois a mixitial bod it contffins asne (an isfins to an the coules asthane aabove fmerizatwever b

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

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)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

zation oogen in50 to 20f liquidlation cfinerysh a catacarbonsore comxture oiling potains pas exempsoparafaromatonversiexempas showfour mation ofboth thof parafthe ca00 cubinaphthcolumn is gasolialyticand a cmplex mof veryoint of aaraffinplified iffin) asicson oflified bn belowajornormale

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

ffinstalyticic metehais calledinecatalytmoleculemanyabout 3insbywersdices5naphthene (cyclic paraffins) and aromatic hydrocarbons ranging from thosecontaining 4 carbon atoms to those containing about 10 or 11 carbon atomslight naphtha containing most (but not all) of the hydrocarbons with 6 orless carbon atoms and a heavy naphtha containing most (but not all) of thehydrocarbons with more than 6 carbon atoms The heavy naphtha has aninitial boiling point of about 140 to 150 degC and a final boiling point of about190 to 205 degC The naphthas derived from the distillation of crude oils arereferred to as straight-run naphthasIt is the straight-run heavy naphtha that is usually processed in a catalyticreformer because the light naphtha has molecules with 6 or less carbonatoms which when reformed tend to crack into butane and lower molecular

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

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T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

weight hydrocarbons which are not useful as high-octane gasoline blendingcomponents Also the molecules with 6 carbon atoms tend to form aromaticswhich is undesirable because governmental environmental regulations in anumber of countries limit the amount of aromatics (most particularlybenzene) that gasoline may containKey specifications of Petrol BS-II BS-IIIEuro-III equivalentEuro-IVRegular Premium Regular PremiumSulphur ppm w(max)500 150 150 50 50Benzene Vol (max)3 1 1 1 1RON (min) 88 91 95 91 95Aromatics Vol (max)NoSpec42 42 35 35Olifins Vol (max) NoSpec21 18 21 18TEMPSL E(KGCNO1 F02 F3 R4 R5 HS6 H7 SA18 S

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

19 S-10 RPERATEQUIPCM2G)FEED B02-EE-0FURNAREACTOREACTOHYDROSEPARAHYDROPURSTRIPPAFTER145STRIPP1270STRIPPREFLUXTURE ampMENTBEFORE001ACE ILOR ILOR OLO-TREAATORO-TREAGEPER FEEEXCHAPER OVPER BOXPRESE6

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

283333ATER4ATEREDANGERVER-HEATTOM25SSURETEMEO650 (T853 (T300 (T300450 (T1860 (AD136144 (PI2250 (585 (TCONDMPERATOR STI-1112)TI-1114)TI-1122)37TI-1203TI-13110I-1303)TI-1316TI-1313)DITIOTURE (SOR)650)3250

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

)3700700)4501)1860)1446)2250)573N 0C)EO2091761651501300 1450 -----182PRESR95 (PI-1100 (PI-11005 (P(T--(PI-13amp PI-13SURESOR20917602) 16503) 150130PI-1302TI-1312----04 182305)R

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

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T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

965002)2)-2BRIEF PROCESS DESCRIPTION(I)NAPHTHA SPLITTER UNIT (NSU) IBP-140 0C cut naphtha from storage (TK 250 251 252) is fed tosplitter column 01-CC-001 under flow control by off site pump 41-PA-1ABat tray No 14 The feed is heated up to 95 0C in splitter feedbottomexchanger 01-EE-001 AB against splitter bottom stream before itenters the column The over head vapours are totally condensed in air condensers 01-EA-001The liquid collected is pumped by splitter reflux pump 01-PA-001 AB andone part sent as top reflux back to the column under flow control 02-FC-1102 to maintain the top temperature The balance which constitutes theIBP-70 0C cut naphtha is sent to storage under reflux drum level control01-LC-1101 after cooling in a water cooler 01-EE-002 Reflux drum bootwater is drained in OWS manually The pressure of splitter is controlled at reflux drum by passing a part ofhot column overhead vapours around the condenser or releasing the refluxvapours to flare through a split range controller (01-PC-1101) The splitter bottom product which constitutes 70-140 0C cut naphtha ispumped to spliter feedbottom exchanger 01-EE-001 AB by hydro

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

treater feed pumps 01-PA-003 AB The bottom product afterexchanging heat with feed is split into two streams One is fed to thehydro treater unit at a temp of 65 0C and the other is sent to storageunder column level control 01-LC-1102 after being colled in splitterbottom column 01-EE-003 The heat necessary for splitter reboiling is supplied by splitter reboilerfurnace 01-FF-001 and desired temperature maintained by controlling thefuel firing The circulation through reboiler is provided by splitterreboiler pumps 01-PA-002 AB 01-FF-001 is double pass verticalcylinderical furnace having four burners fired from the bottom It hassoot blowing facility for convection section(II)HYDROTREATER UNIT (HTU) REACTION AND SEPARATION SECTION The naphtha from NSU is fed to HTU by a pump 01-PA-003 AB Thefeed flow is controlled by flow control valve 02-FC-1101 The feed thenmixed with Rich Hydrogen Gas from HP separator of reformer The RichHydrogen gas flow is controlled by 02-FC-1202 Both the liquid naphthaand rich hydrogen gas are pre-heated in a series of exchangers 02-EE-001 ABCDEF which are feedreactor effluent heat exchangersThen mixture is heated upto reaction temperature in a furnace 02-FF-001and fed to the reactor 02-RB-001 The furnace 02-FF-001 is four passhaving three burners fired from bottom The furnace is having facility ofsoot blowing The reactor inlet temperature is maintained by 02-TC-1101

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

cascaded with either fuel oil or fuel gas PCs The furnace is providedwith all safety shut down inter locks It has also provision of decoking The desulfurisation and hydro treating reaction takes place in 02-RB-001at almost constant temperature since heat of reaction is quite negligibleThe reactor is provided with facility of steam and air for regeneration ofcatalyst The catalyst for reactor is HR-306 The reactor catalyst bed has been provided with five number of thermocouple points at various location to get the bed temperature duringregeneration of the catalyst The reactor effluent after having heat exchanged in 02-EE-001 serieswith feed goes to air cooler 02-EA-001 The air cooler fans pitch isvariable ie cooling load can be adjusted as per situation requirementAfter air cooler the effluent is cooled in a trim cooler 02-EE-002 Theproduct is collected in a separator vessel 02-VV-001 Sour water isdrained from the separator drum boot manually The separator drumpressure is maintained by 02-PC-1201 releasing the excess gas in FGsystem In event of emergency the separator excess pressure can bereleased to flare through an on-off cv HV-1201 A line has been provided to feed the naphtha to stripper during start upbypassing the reactionseparation sectionSTRIPPER SECTION The separator liquid is pumped by 02-PA-001AB under flow control 02-FC-1201 cascaded with 02-LC-1201 to stripper feedbottom exchanger

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

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T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

02-EE-003 ABC when it gets heat exchanged by hot stripper bottomstream The stripper column consists of 28 Nos of valve trays one to eightnumber of trays are single pass and the rest double pass Feed comingfrom 02-EE-003 ABC enters at 9th tray from two sides The over headvapours are cooled down in 02-EA-002 air condenser and collected in 02-VV-002 stripper refflux drum The fan load can be adjusted Thecondensed hydro-carbons are returned to column top by pump 02-PA-002AB under flow control 02-FC-1301 cascaded with 02-LC-1302 asreflux to maintain the top temp The water accumulated in the boot issent for disposal as sour water The reflux drum pressure is maintainedby 02-PC-1301 releasing excess gas in the FG system The facility is thereto inject corrosion inhibitor by pump 02-PA-005A Stripper bottom product exchanged heat with stripper feed in 02-EE-003ABC and then sent to reformer as hot feed The excess or requiredhydro-treated naphtha is sent to storage after being cooled in 02-EE-004AB under level control 02-LC-1301 The necessary heat for stripper reboiling is supplied by 02-FF-002reboiler heater 02-CC-001 product is circulated through 02-FF-002single pass cylinders vertical furnace by 02-PA-003 AB Partialvapatsaf HypremixTh

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

folbrohea Asreasen In03 Thand00excdowpourizat3rd plafety intdro treessure bxed wite mixedlowedought uater 03the reactor efnt to ththe sam-FF-00e efflud send2) andchangerwn suction occate froter lockeated nbyth recyd feedby feeupto th

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

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MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

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DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

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hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

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nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

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r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

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s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

3-FF-00eactionffluenthe seconme way3 prioruent frofor head stablrs is coccesivelcurs inm theksnaphtha03-Pycle gasis preedefflue react01 and tn is endt is heatnd reac03-RBtobe fom theat recoizer reombinedly in t02-FFbottoma fromPA-001s fromheateduent extion temthen fedo-therted in t

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

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nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

ctor 03-002 effed to tlast revery paeboilerd by a tthe Ze-002 Rm of 02-hydroAB unm the rd in thexchangemperatd to 1strmic ththe firs-RB-00ffluentthe thireactorarallely(03-Ehese waeemannReboilin-CC-00treatender floecyclefeed-eer 03-Eure (48t reacthe temst inter02is heatrd reac03-RBto

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

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withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

feeE-003)ay valveSecatng is co1 Furner unitow contgas coeffluenEE-00280 0C)or 03-Rmperatuheaterted in tctor 03--003 isdefflu) Thee 03-TIthen exntrolledace is pis pumtrol 03-ompresst excha2 Thenby heaRB-001re dror 03-FFhe seco-RB-00split iuent exoutletIC-1101xchangd by 02provide

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

mped to-FC-110sor (03anger 0n the mating inps soF-002 pond inte3nto twoxchangefrom1 and ther (032-TC-13ed witho requir1 AB a3-KA-0003-EE-0mixturen the pthe fiprior toer heato streaer (03-Ethe then coo3-EE-00301allredand01)001e isrerstbeer

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

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withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

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vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

amsEEtwoled01)reformer effluent cooler 03-EA-001 and effluent trim cooler 03-EE-004The cooled reactor effluent is flashed in the reformer separator 03-VV-001 Vapour and liquid phase are separated in separator 03-VV-001 Part ofthe gas phase constitutes the hydrogen recycle gas to the reactorcirculated by recycle gas compressor 03-KA-001 Remaining amountcorresponding to the amount of gas produced is compressed by thehydrogen rich gas compressor 03-KA-002 AB The pressure control inseparator is achieved by a kick back gas flow from HP Absorber (03-VV-003) to separator Should the gas be produced in excess to 03-KA-002AB capacity degassing in split range to fuel gas is performed through03-PC-1401 A and 03-PC-1402 The separator liquid is sent by reformer separator bottom pumps (03-PA-002 AB) under level control 03-LC-1401 for recontacting with the gascompressed by 03-KA-002 AB The hot flue gases from all the three reformer furnaces are combinedand sent to stream generation system forwaste heat recovery to produceMP steam Provision is there to dry the recycle gas into a dryer (03-RB-004) The dryer can later be regenerated The unit has also been provided with facilities for continuous chloridingwater injection DMDSCcl4 injection and caustic soda circulation

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

The separator (03-VV-001) vapour after passing through KO drum (03-VV-002) is compressed in the H2 Rich Gas Compressor (03-KA-002 AB)and recontacted with separator liquid The recontacted vapour and liquidis cooled in a cooler (03-EE-005) and then fed to HP absorber (03-VV-003) The aim of this device is to allow for high recovery of the C5contained in the gas phase of separator and improve the quality (H2concentration) of the produced gas A part of hydrogen rich vapour goes to HTU as a make up hydrogen andbalance goes to the fuel gas system under pressure control 03-PC-1601 The liquid from the 03-VV-003 is drawn off under level control 03-LC-1601 and mixed with stabilizer vapour distillate The combined stream iscooled in LPG absorber feed cooler 03-EE-006 and flashed in LPGabsorber Off-gas is sent under pressure control to fuel gas system Theliquid from 03-VV-004 is pumped by stabilizer feed pumps 03-PA-003AB After pre heating in stabilizer feedbottom exchanger 03-EE-007the mixture is fed to the stabilizer 03-CC-001 at tray No 13 Stabilizer over head vapours are partialy condensed in stablizercondenser 03-EE-008 and flashed in stabilizer reflux drum 03-VV-005The vapour phase is sent to LPG absorber for C3 and C4 recovery A partof condensed liquid is pumped as reflux to the column by stabilizer refluxpump 03-PA-004 AB under the flow control and the balance is sent toLPG Recovery Unit under level control of reflux drum

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

The heat of reboiling to the stabilizer is provided by the hot reactoreffluent in the stabilizer reboiler 03-EE-003 and the desiredtemperature maintained by controlling the flow of reactor effluent by thethree way valve The bottom product stabilized reformate is cooled in the feedbottomexchanger 03-EE-007followed by reformate cooler 03-EA-002 andreformate trim cooler 03-EE-009 before being routed to storage Tk 77to 84

FLUIDISED CATALYTIC CRACKING Fluid catalytic cracking (FCC) is the most important conversion processused in petroleum refineries It is widely used to convert the high-boilinghigh-molecular weight hydrocarbon fractions of petroleum crude oils tomore valuable gasoline olefinic gases and other products Cracking ofpetroleum hydrocarbons was originally done by thermal cracking which hasbeen almost completely replaced by catalytic cracking because it producesmore gasoline with a higher octane rating It also produces byproductgases that are more olefinic and hence more valuable than thoseproduced by thermal cracking The feedstock to an FCC is usually that portion of the crude oil that hasan initial boiling point of 340 degC or higher at atmospheric pressure and anaverage molecular weight ranging from about 200 to 600 or higher Thisportion of crude oil is often referred to as heavy gas oil The FCC processvaporizes and breaks the long-chain molecules of the high-boiling

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

hydrocarbon liquids into much shorter molecules by contacting thefeedstock at high temperature and moderate pressure with a fluidizedpowdered catalyst In effect refineries use fluid catalytic cracking to correct the imbalancebetween the market demand for gasoline and the excess of heavy highboiling range products resulting from the distillation of crude oil The first commercial use of catalytic cracking occurred in 1915 whenAlmer M McAfee of the Gulf Refining Company developed a batchprocess using aluminum chloride (a Friedel Crafts catalyst known since1877) to catalytically crack heavy petroleum oils However the prohibitivecost of the catalyst prevented the widespread use of McAfees processat that time Thhouma Thdevtharefdes Basstconregregdes Side modeurs a daaintenanere areveloped

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

at mustfining csignsicallytackedntainedgeneratgeneratsignersde-by-sern FCCay for ancee a numbd for mot be purompanythere atype win a sintor andtor areand licside conunits aas muchber ofodern Frchasedy desiriare twowhere thngle vesthe siin twocensorsnfiguratare all ch as 2 tdiffereFCC unitd from t

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

ng to coo differhe reacssel witide-by-sseparattioncontinuoo 3 yeaent propts Eachthe desonstrucrent conctor andth the rside tyte vessous proars betwprietaryh designsign devct and onfiguratd the careactorype wheels Thecessesween shy design is avaveloperoperatetions foatalystaboveere theese arewhich o

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

hutdownns thatailable uby anye an FCCor an FCregenethe cate reactoe the maoperatens for rt have bunder apetroleC of a gCC uniterator atalystor and cajor FCe 24routinebeenlicenseeumgiven thearecatalystCCet CBampI Lummus ExxonMobil Research and Engineering (EMRE) Shell Global Solutions International Stone amp Webster Engineering Corporation (SWECO) InstitutFrancais Petrole (IFP) Universal Oil Products (UOP) - currently fully owned subsidiary ofHoneywellReactor and Regenerator

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

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nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

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r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

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kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

The schematic flow diagram of a typical modern FCC unit in Figure 1 belowis based upon the side-by-side configuration The preheated high-boilingpetroleum feedstock (at about 315 to 430 degC) consisting of long-chainhydrocarbon molecules is combined with recycle slurry oil from thebottom of the distillation column and injected into the catalyst riserwhere it is vaporized and cracked into smaller molecules of vapor bycontact and mixing with the very hot powdered catalyst from theregenerator All of the cracking reactions take place in the catalyst riserThe hydrocarbon vapors fluidize the powdered catalyst and the mixtureof hydrocarbon vapors and catalyst flows upward to enter the reactor ata temperature of about 535 degC and a pressure of about 172 barg The reactor is in fact merely a vessel in which the cracked product vaporsare (a) separated from the so-called spent catalyst by flowing through aset of two-stage cyclones within the reactor and (b) the spent catalystflows downward through a steam stripping section to remove anyhydrocarbon vapors before the spent catalyst returns to the catalystregenerator The flow of spent catalyst to the regenerator is regulatedby a slide valve in the spent catalyst line Since the cracking reactions produce some carbonaceous material(referred to as coke) that deposits on the catalyst and very quicklyreduces the catalyst reactivity the catalyst is regenerated by burningoff the deposited coke with air blown into the regenerator The

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

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by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

regenerator operates at a temperature of about 715 degC and a pressure ofabout 241 barg The combustion of the coke is exothermic and itproduces a large amount of heat that is partially absorbed by theregenerated catalyst and provides the heat required for the vaporizationof the feedstock and the endothermic cracking reactions that take placein the catalyst riser For that reason FCC units are often referred to asbeing heat balanced The hot catalyst (at about 715 degC) leaving the regenerator flows into acatalyst withdrawal well where any entrained combustion flue gases areallowed to escape and flow back into the upper part to the regeneratorThe flow of regenerated catalyst to the feedstock injection point belowthe catalyst riser is regulated by a slide valve in the regenerated catalystline The hot flue gas exits the regenerator after passing throughmultiple sets of two-stage cylones that remove entrained catalyst fromthe flue gas The amount of catalyst circulating between the regenerator and thereactor amounts to about 5 kg per kg of feedstock which is equivalent toabout 466 kg per litre of feedstock Thus an FCC unit processing 75000barrelsday (12000000 litresday) will circulate about 55900 metrictons per day of catalystDistillation column The reaction product vapors (at 535 degC and a pressure of 172 barg) flowfrom the top of the reactor to the bottom section of the distillation

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

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withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

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d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

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r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

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s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

column (commonly referred to as the main fractionator) where they aredistilled into the FCC end products of cracked naphtha fuel oil andoffgas After further processing for removal of sulfur compounds thecracked naphtha becomes a high-octane component of the refinerysblended gasolines The main fractionator offgas is sent to what is called a gas recovery unitwhere it is separated into butanes and butylenes propane and propyleneand lower molecular weight gases (hydrogen methane ethylene andethane) Some FCC gas recovery units may also separate out some of theethane and ethylene Although the schematic flow diagram above depicts the main fractionatoras having only one sidecut stripper and one fuel oil product many FCCmain fractionators have two sidecut strippers and produce a light fuel oiland a heavy fuel oil Likewise many FCC main fractionators produce a lightcracked naphtha and a heavy cracked naphtha The terminology light andheavy in this context refers to the product boiling ranges with lightproducts having a lower boiling range than heavy products The bottom product oil from the main fractionator contains residualcatalyst particles which were not completely removed by the cyclones inthe top of the reactor For that reason the bottom product oil isreferred to as a slurry oil Part of that slurry oil is recycled back into themain fractionator above the entry point of the hot reaction productvapors so as to cool and partially condense the reaction product vapors as

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

they enter the main fractionator The remainder of the slurry oil ispumped through a slurry settler The bottom oil from the slurry settlercontains most of the slurry oil catalyst particles and is recycled back intothe catalyst riser by combining it with the FCC feedstock oil The socalledclarified slurry oil or decant oil is withdrawn from the top of slurrysettler for use elsewhere in the refinery or as a heavy fuel oil blendingcomponentRegenerator flue gas Depending on the choice of FCC design the combustion in the regeneratorof the coke on the spent catalyst may or may not be complete combustionto carbon dioxide (CO2) The combustion air flow is controlled so as toprovide the desired ratio of carbon monoxide (CO) to carbon dioxide foreach specific FCC design[1][4]

In the design shown in Figure 1 the coke has only been partiallycombusted to CO2 The combustion flue gas (containing CO and CO2) at715 degC and at a pressure of 241 barg is routed through a secondarycatalyst separator containing swirl tubes designed to remove 70 to 90percent of the particulates in the flue gas leaving the regenerator[8] Thisis required to prevent erosion damage to the blades in the turboexpanderthat the flue gas is next routed through The expansion of flue gas through a turbo-expander provides sufficientpower to drive the regenerators combustion air compressor Theelectrical motor-generator can consume or produce electrical power If

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

the expansion of the flue gas does not provide enough power to drive theair compressor the electric motorgenerator provides the neededadditional power If the flue gas expansion provides more power thanneeded to drive the air compressor than the electric motorgeneratorconverts the excess power into electric power and exports it to therefinerys electrical system[3]

The expanded flue gas is then routed through a steam-generating boiler(referred to as a CO boiler) where the carbon monoxide in the flue gas isburned as fuel to provide steam for use in the refinery as well as tocomply with any applicable environmental regulatory limits on carbonmonoxide emissions[3]

The flue gas is finally processed through an electrostatic precipitator(ESP) to remove residual particulate matter to comply with any applicableenvironmental regulations regarding particulate emissions The ESPremoves particulates in the size range of 2 to 20 microns from the fluegas[3]

The steam turbine in the flue gas processing system (shown in the abovediagram) is used to drive the regenerators combustion air compressorduring start-ups of the FCC unit until there is sufficient combustion fluegas to take over that task

COKER AGENERAL DATA1 Capacity 06 MMTPA2 On-stream hours per year 72003 Original Technology Russian4 Year of Commissioning 19645 Turn Down 95

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

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nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

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r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

The unit is designed for the following three cases-CASE-I Feed corresponding to future refinery configuration having ResidDesulphurisation unit while processing 60 MMTPA high sulphur crude5050 wt Arab mix)CASE-II Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 60 MMTPA low sulphur crude(Bonny light)CASE-III Feed corresponding to future refinery configuration without ResidDesulphurisation while processing 42 MMTPA low sulphur crude(Bonny light)PROCESS DESCRIPTIONDelayed cokingrsquo process is an effective conversion process for upgradationof the heavy residuals from the refinery distillation unit into valuabledistillates and premium quality petroleum cokeIn this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period in largeinsulated vessels called coke drums During this time the heavy stockundergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the same timesome reactive molecules undergoes pyrolytic polymerization forming fuel oiland coke Coke is formed by two different mechanism In one the colloidalsuspension of the asphltene and resin components is re-arranged resulting inthe precipitation of the compounds to form highly-cross-linked structure ofamorphous coke The compounds are also subjected to a cleavage of thissulphatic groups Coke formed from these resinasphatene compounds isundesirable for making premium grade cokeThe other reaction mechanism involves the polymerisation and condensationof aromatics grouping a large number of these compounds to such a degree

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

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kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

that eventually coke is formed The coke produced from these aeromaticcompounds is the most suitable premium grade needle coke The otherproducts of pyrolysis are separated into distillate fuels and recoveredseparately in a fractionator columnReduced crude is received in the Feed Surge Drum in Coker-A throughoffsite Pumps The feed RCO is then preheated to 240degC by heat exchangeragainst Coker products like Coker Kero Light Diesel Oil (LDO) Product andLDO CRThe preheated RCO is fed to fractionator column at two levels one belowand the other above the vapour inlet nozzle This facility is provided tocontrol fractionator bottom temperatureThe feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 340 ndash 360 degC and thematerial is heated to the temperature of 500degC which resulted in partialvapourization and mild cracking of the stock The vapour liquid mixture thenenters the coke chamber which is in coking service where the vapourexperience further cracking as it passes through the coke chamber and theliquid experience successive cracking and polymerization until it is convertedto vapour and coke The unit has two blocks and each block has two cokechambers one in coking service while the other is being decoked with highpressure water jets Each block has got individual heaterThe coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gas and

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

naphtha are obtained as overhead products and kerosene LDO and CFO asside draw off products Kerosene LDO and CFO are steam stripped in thestripper columns cooled prior to their being routed to their destinationsA LDO circulating reflux stream is drawn and is utilised for HP steamgeneration LDO Product CFO Product and FO IR are utilized for generatingMP steam A cold LDO stream is used as quench in the quench columnBesides refinery slop and gas oil from offsites tank can be used as quench inthe vapour line of the coke chambersThe residue from the bottom of quench column is sent to storage afterfurther coolingThe vapour from the fractionator overhead are cooled in air cooler andwater condensers and then led to reflux drum where gas and liquid separateout The gases from the fractionator reflux drum sent to LPG Recovery unitof the refinery Condensed naphtha from reflux drum is also routed to theLPG recovering unit for stablilization A part of condensed naphtha sentback to fractionator column as top refluxCoke from the cooled drained chamber is cut and cleared by hydraulic jetsoperating at a pressure of about 200 Kgcmsup2 Coke along with water falls tothe ground The coke from the drop-out area is sent to storage using CokeSizer and conveyors

COKER BPROCESS DESCRIPTION Delayed cokingrsquo process is an effective conversion process forupgradation of the heavy residuals from the refinery distillation unit intovaluable distillates and premium quality petroleum coke

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

In this process the heavy residual feed stocks are heated up to cokingtemperature and the mixture is allowed to stand for prolong period inlarge insulated vessels called coke drums During this time the heavystock undergoes thermal cracking at large high bpt HC molecules aredecomposed into smaller lower boiling point molecules and at the sametime some reactive molecules undergoes pyrolytic polymerization formingfuel oil and coke Coke is formed by two different mechanism In one thecolloidal suspension of the asphltene and resin components is re-arrangedresulting in the precipitation of the compounds to form highly-crosslinkedstructure of amorphous coke The compounds are also subjected toa cleavage of this sulphatic groups Coke formed from theseresinasphatene compounds is undesirable for making premium grade coke The other reaction mechanism involves the polymerisation andcondensation of aromatics grouping a large number of these compoundsto such a degree that eventually coke is formed The coke produced fromthese aeromatic compounds is the most suitable premium grade needlecoke The other products of pyrolysis are separated into distillate fuelsand recovered separately in a fractionator column Reduced crude is received in Coker-B from offsite storage tanks by a 18rdquodia pipeline The feed stock RCO from storage is preheated to 200degC byheat exchanger against Coker products like Coker Kero heavy gas oil(HGO) coker fuel oil (CFO) and residue

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

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hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

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r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

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s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

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ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

The preheated RCO is further heated to 240degC in the pre-heat section ofthe coker furnace and fed to fractionator column This feed goes to thefractionator is at two levels one below and the other above the vapourinlet nozzle This facility is provided to control fractionator bottomtemperature The feed material along with the recycle stock is pumped to the reactioncoils of the coker furnace at a temperature of 380degC The material isheated to a temperature of 500degC which resulted in partial vapourizationand mild cracking of the stock The vapour liquid mixture then enters thecoke chamber which is in coking service where the vapour experiencefurther cracking as it passes through the coke chamber and the liquidexperience successive cracking and polymerization until it is converted tovapour and coke The unit has two coke chambers one in coking servicewhile the other is being decoked with high pressure water jets The coke chamber overhead vapours enter the fractionator via a quenchcolumn at a temperature of about 425degC In the fractionator column gasand naphtha are obtained as overhead products and kerosene HGO andCFO as side draw off products Kerosene and HGO are steam stripped inthe stripper columns cooled prior to their being routed to theirdestinations

HYDROGEN GENERATION UNITGENERAL DATADesign Capacity 34 TMT H2 productionStream Factor 8000 hours per yearTurn down ratio 30 Original Technology Haldor Topsoe

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Date of Commissioning 24 TH Aprirsquo2002BRIEF PROCESS DESCRIPTIONTo meet the make up requirement of Hydrogen for DHDT Unit naphthasteam reforming type Hydrogen unit has been considered whereHydrogen is produced by steam reforming of Naphtha Naphtha isfirst desulphurised over a desulphurisation catalyst where in presenceof hydrogen non-reactive sulphur compounds are hydrogenated tohydrogen sulphide which is then absorbed on Zince Oxide beds Thedesulphurised feed is mixed with preheated steam and then heated tothe desired temperature before entering steam reforming furnacetubes containing a nickel based catalyst The reformed gases leave thetubes and after exchanging heat to generate steam pass through a COshift convertor where most of the carbon monoxide is reacted withexcess steam to produce additional hydrogen and carbon dioxide Theconverted gases leave the reactor and preheat the incoming NaphthaBoiler Feed water and Demineralised water The impurities like carbonmonoxide carbon dioxide methane nitrogen and water vapour areremoved by high pressure adsorption on molecular sieves Activatedcarbon and alumina gel in PSA (Pressure Swing Adsorption) system Alladsorbed gases are removed during deadsorption amp regeneration of thebeds and used as fuel in reformer furnace and Hydrogen with 995(vol) purity is fed to bullet DHDT unitFeed Stock DESIGNCASE 1 30 (WT) MIXTURE OF

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

RFCCU OFF GAS AND 70 (WT)SRNCASE 2 100 CAPACITY ON SRNType of Feed GAS LIQUIDFeed composition For Liq Feed(SRN ndashC5-90OCCUT)For gas feed(RFFCU OFFGASES)ATACHED AS ANNEXURE-1Gas MW -Feed Characteristics For Liq Feed For gas feed(SRN ndashC5-90OCCUT)(RFFCU OFFGASES)Liq Sp Gravity 150C 0692Feed composition TBP ATACHED ASANNEXURE-1ATACHED ASANNEXURE-1Cut range degC C5-90OC -Total Sulfur Nitrogen WT 0025 NIL -PONA Vol ATACHED ASANNEXURE-1-Distillation ASTM D86 OCIBP 4110 VOL 4450 VOL 5970 VOL 71FBP 98-Calorific Value KcalKg 10492 -CH Ratio wt wt 57 -Any other additional feed to PSA unitFeed Type -Flow rate (Kghr) -Fuel Type Flow rate (Kghr)Liquid Naphtha Purge gas from PSA Syn Gas (incase PSA shut down)-Internal fuel to Furnace (off Gas from PSA)NM3HrCASE-1CASE-2PSA ndashI OFF GAS 2525025845

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Steamcarbon ratio for the feed for SteamReforming-Blow down 2nd Demister vent quantities Kghr -Inlet temperature to the tabular Reformer degC640Reformer exit temperature Deg C 930Pressure around the reformerinlet of reformer Kgcm2 a out let of reformerKgcm2 a242Efficiency of PSA -Whether pre-reformer is used (YesNo) YESOperating condition for pre-reformer PressureKgcm2 a (Inlet Outlet) Temperature degC(Inlet Outlet)284 ndash279 490 -419Pre-reformer location (Afterbefore feedpreheat coil)BEFORE FEED PREHEAT COILNo of Stages of Reforming SINGLEFeed temperaturepressure unit bl (degCKgcm2 a)SRN (C5 ndash90) RICH GASESFROM RFCCU40 50 51 135Product temperaturepressure unit bl (degCKgcm2 a)45 (MAX) 21 (MIN)Product Quality (Percent purity of Hydrogen)999Product yield (NM3hr) 47252Extent of Air cooling degC 20Product run down temperature cooler inlet degC 131DM water heater heating (by syngas) if anyTemperature of syn gas to the Exchanger degC 270 331 224Heat recovered (MM Kcalhr) 229 422 330Flue gas heat recoveryAir pre-Heaters for the furnace Type of air Pre-Heater (MM Kcalhr)915 + 485Steam generation duty in furnace (MM Kcalhr)904Steam superheating duty in furnace (MM Kcalhr)784Feed super heating duty in furnace (MMKcalhr)426 + 412Final flue gas temperature degC 159

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Cooling Water Design DataType (Once thrucirculating SeaWater) Circulating WaterFlow Rate (m3hr) 120Supply return temperature (oC) 33 42Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam 686 360 - 326MP Steam - - -LP Steam - 20 + 20Others if any - - -Operating Pressure amp Temperature(Kgcm2a) oC)HP Steam360 400MP Steam 11 275LP Steam 45 180Total Power Consumption in HGU (KW) 2000

DGEN D S T O DFEEThesulsulfrobel

DIESNERALDesignStreamTurndoOriginaDate ofEDSTOe desigphur imphur im

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

om FCClow me

EL HL DATACapacim Factownl Technf CommOCK DEn feedmportemporteCU (TCOntioned

HYDROAty r 40nologyissioninEFINITis a bld cruded crudeO) Lighd prope

OTRE22 M8000 of de UOPng 20T

TIONend cone (SRGe fromht Cokeerties

EATI

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

MMTPA0 hoursesign caP USATH Octrsquo2ntainingO-LS)middleer Gaso(Table

INGs per yeapacity2002g StraiStraige east (oil fromII-1)

UNITearyight rught runSRGOmCoker

T ( Dn GasoGasoil-HS) Tr unit (L

DHDTil fromfrom hTotal CyLCGO)

T )lowhighycle Oi

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

withlCase I Case II Case IIICapacity MTPA(BPSD)22 (47460) 22 (47855) 22 (47433)Composition Wt SRGO-LS 460 SRGO-LS 60 SRGO-LS 260SRGO-HS 46 SRGO-HS 480 SRGO-HS 127TCO-FCC 316 TCO-FCC 310 TCO-FCC 392LCGO 178 LCGO 150 LCGO 221Case-1 Case-2 Case-3API 3026 3162 3018Sulphur Wt 0726 192 137Nitrogen wppm 664 610 758Bromine Numberg100g17 16 21Flash Point 1049896 50 50 58Pour Point 1049896 3 3 3Metal Ni+V wppm 086 091 107Iron wppm 03 03 03Cetane Number 424 437 390Silicon wppm 053 045 066Chloride wppm 51 48 62Case I Case II Case IIIASTM DistillateIBP 141 142 13910 192 192 18230 263 259 24850 288 284 28070 309 309 30590 344 348 34395 359 361 358FBP 399 402 399MAKE UP HYDROGENThe make-up hydrogen for the Hydrotreater will be supplied from theHydrogen Unit having the following characteristics-Hydrogen Purity 995 Vol minChloride 1 vppm maxBalance will comprise mainly methane amp trace of CO CO2 and N2PRODUCT SPECIFICATIONThe Hydrotreated products shall be routed to the storage and theproperties of the Diesel will meet the following specification

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Properties DieselFlash Point 1049896 Not less than 40Cetane Number 485Sulphur Wt ppm 2000Pour Point 1049896 Equal to or Not higher than the FeedStability UOP 413 mg100ml lt 16DistillationTemperature for Recovery 855 Vol and 95 Vol Not more than the FeedWater Content 005 Vol maxATTRIBUTES UNITS DESIGNCAPACITY MMTPA 220ATTRIBUTES UNITS DESIGNTrsquoPUT M3Hr 3140CATALYSTSTK-10QuantityLifeFeed ProcessedMTYearsM3Kg of Cat5445TK-711 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178RF200 QuantityLifeFeed ProcessedMTYearsM3Kg of Cat2178HC-K QuantityLifeCycle LengthFeed ProcessedMTYearsYearsM3Kg of Cat

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

52445H2 consumption (SOREOR) NM3M3 OF freshFeed18231912SWEET DIESEL YIELD(SOREOR) Wt of Fresh Feed 96995GAS TO OIL RATIO NM3M3 OF FEED 250-500OPERATING PARAMETERSFURNACE Heat DutyEfficiencyMMKCalHr20089194H2 Partial Pressure KgCm2 59 MinRecycle Gas Purity H2 70 MinREACTOR-1Inlet Pressure(SOREOR)KgCm2

10291024ATTRIBUTES UNITS DESIGNInlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bedQuench Flow0C0CKgCm2

0C0C0CKgHr323370368406313520000REACTOR-2Inlet Pressure(SOREOR)Inlet Temprature(SOREOR)Outlet Temprature(SOREOR)Delta P Across Reactor(EOR)Delta T Across Reactor(EOR)WABT Ist BedWABT IInd bed

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Ist Quench FlowIind Quench FlowKgCm2

0C0CKgCm2

0C0CKgHrKgHr99699132337236840688342160021600HPSEPARATOR Pr KgCm2 845ATTRIBUTES UNITS DESIGNSTRIPPERPressureTop TempratureStripping SteamKgCm2

0CMTHr8516568Utility Summary for DHDTA Cooling Water Design DataType (Once thrucirculatingSeaWater) Circulating WaterFlow Rate (m3hr) 2480Supply return temperature (oC) 33 42B Steam Flow rate (Thr) Generationin the unitConsumption Netimport exportHP Steam - 987 987MP Steam - 106 106LP Steam 870 10 - 860- Operating Pressure ampTemperature (Kgcm2a) oC)HP Steam 360 400

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

MP Steam 11 275LP Steam 45 180Others if any -C Fuel i) Heater absorbed duty (MMKcalhr) -ii) Heater efficiency -iii) Heater fired duty (MM Kcalhr)Or fuel consumed (Thr) 27D Total Power Consumption in HGU(KW) 9183PROCESS DESCRIPTION DHDT is installed for upgradation of Coker Gas Oil as well as qualityimprovement of few diesel components The feed is mixed with Hydrogen-rich recycle gas amp make up Hydrogenafter being compressed in respective compressor and reheated byexchanging heat with hot reactor effluent The mixture is furtherheated to the desired reactor temperature in a fired heater and is fed tothe Hydrotreater reactor Hydrotreating reactions are exothermic in nature and hence recycle gasis introduced as quench between the beds of the reactor to cool reactionfluid and redistribute vapour and liquid The reactor effluent is cooled by heat exchange with feed and recyclegas before it is finally cooled in the air cooler and then flashed in theseparator The hydrogen rich separator gas is scrubbed with Lean Aminein Recycle Gas Amine scrubber to remove H2S recompressed andcombined with make up hydrogen coming from the Hydrogen plant andthen returned to the reactor Sour water is coalesced and removed from

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

the bottom of the separator and sent to Sour Water Stripper Unit The liquid from the separator is sent to a stripper via heat exchangerspart of the condensed stripper overhead is pumped to stripper as refluxand rest is taken out as naphtha product The uncondensed vapour exstripper is sent to Amine Absorption Unit The bottom product fromstripper gas to storage as hydrotreated gas oil component after cooling

OIL MOVEMENT amp STORAGEOil Movement amp Storage (OM amp S) is an important function of the ProductionDepartment In Barauni Refinery OM amp S section consists of the followingsub sections OM amp S - Receipt OM amp S - Despatch LPG Utilities Coke HandlingOM amp S PUMPSA Crude and Intermediate Product are pumped through centrifugal pumpsBesides there are booster pumps in the pipelines and transfer pumps tothe marketingBFinished Product Pumps of centrifugal type are present to pump thefinished products like SRN MS MRN SKO HSD LDO LSHS caustictransfer slack and paraffin wax Phenol Extract CBFS FO LPG BottlingLPG bulk loading LPG Intank pump for bulk loading from Mounded bulletsTANK WAGON LOADING GANTRYA White Oil Loading GantryMaximum 38 number of BG TWs can be placed in one line for the products

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

(SRNMSSKOHSD) 24 numbers of BTPN TWs can be placed in one lineBBlack Oil Loading GantryIt has two rail lines both lines have BG and MG tracks In this gantryloading of LDOPhenol ExtractLSHS can be done in BGMG Tank wagonsFOLDO points are multiple and LSHSPhenol Extract points are commonCLube Oil Loading GantryIt has two rail lines known as line no 5 and 6 only BG TWs can be loadedin this gantry with CBFS-500 Rubber Extender Oil However none of aboveproducts are loaded now in this gantryLPGStorage in Horizontal tanks(bullets) Horton spheres(presently there arefour) Horton spheres service These are Two of capacity 300 M3 amp Two ofcapacity 1500 M3 each and 6 nos Mounded bullets capacity 1500 M3 each

UTIITIESPROCESS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Both21 No of cells 5Min Nor Max22 Supply Press KgCm2 50 - -23 Design wet bulb temp oC 290 - -24 Supply temp oC 330 - -25 Return temp oC 450 - -26 Return Press KgCm2 (a)At the top of cooling tower0329 If any treatment done YesIf yes Detailes Non -oxidising biocides used211 Cooling water circulatingpumps7 motors2111 Type Centrifugal2112 No (Working+ standby) 4 working +3 standby

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

2113 Capacity M3 Hr ( Rated Normal)38252114 Head KgCm2 502115 Power Consumption KW(Rated Normal 720 kw (each)CRU COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water or seawater)Circulating fresh water21 No of cells 2Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 33025 Return temp oC 45026 Return Press KgCm2 (a)At the top of cooling tower3-529 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 50211 Cooling water circulating pumps 2 nos2111 Type Centrifugal2112 No (Working+ standby) 1 working +1 standby2113 Capacity M3 Hr ( Rated Normal)12002114 Head KgCm2 562115 Power Consumption KW (Rated Normal 160BXP COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulating fresh water orsea water)Circulating fresh water21 No of cells 5Min Nor Max22 Supply Press KgCm2 (a) 50-6023 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 45026 Return Press KgCm2 (a) 3-5At the top of cooling

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

tower29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3

Hr-211 Cooling water circulatingpumps5 nos2111 Type Centrifugal2112 No (Working+ standby) 3 working +2 standby2113 Capacity M3 Hr ( Rated Normal)44502114 Head KgCm2 512115 Power Consumption KW(Rated Normal 66 (each)TPS COOLING WATER SYSTEM10 Cooling Water20 Type (Once through Circulatingfresh water or sea water)Circulating fresh water21 No of cells 3Min Nor Max22 Supply Press KgCm2 (a) 3523 Design wet bulb temp oC 29024 Supply temp oC 32025 Return temp oC 4026 Return Press KgCm2 (a)At the top of cooling tower2527 Blow Down Quantity M3 Hr(continuous)75-10028 Cooling water balance M3 Hr Total to TPS29 If any treatment done YesIf yes Detailes Non -oxidising biocides used210 Cooling water Make up M3 Hr 75211 Cooling water circulating pumps 3 nos2111 Type Centrifugal2112 No (Working+ standby) 2 working +1 standby2113 Capacity M3 Hr ( Rated Normal) 36002114 Head KgCm2 512115 Power Consumption KW (Rated Normal 450

UTILITIES

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

A gas flare alternatively known as a flare stack is an elevated verticalconveyance found accompanying the presence of oil and gas wells rigsrefineries chemical plants natural gas plants and landfills They are usedto eliminate waste gas which is otherwise not feasible to use or transportThey also act as safety systems for non-waste gas and is released viapressure relief valve when needed to ease the strain on equipment Theyprotect gas processing equipments from being overpressured Also in caseof an emergency situation the flare system helps burn out the totalreserve gasThe size and brightness of the resulting flame depends upon how muchflammable material was released Steam can be injected into the flame toreduce the formation of black smoke The injected steam does howevermake the burning of gas sound louder which can cause complaints fromnearby residents Compared to the emission of black smoke it can be seenas a valid trade off In more advanced flare tip designs if the steam usedis too wet it can freeze just below the tip disrupting operations andcausing the formation of large icicles In order to keep the flare systemfunctional a small amount of gas is continuously burned like a pilot light sothat the system is always ready for its primary purpose as an over-pressuresafety system The continuous gas source also helps diluted mixturesachieve complete combustionFlare gas recovery system

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

There are two compressors for recovery of waste flare gas compressing thesame and put it back to refinery fuel gas header for consumption in furnaceboilers Capacity of each compressor is 450 NM3HrWater treatmentMany industries have a need to treat water to obtain very high quality waterfor demanding purposes Water treatment produces organic and mineralsludges from filtration and sedimentation Ion exchange using natural orsynthetic resins removes calcium magnesium and carbonate ions from waterreplacing them with hydrogen and hydroxyl ions Regeneration of ionexchange columns with strong acids and alkalis produces a wastewater rich inhardness ions which are readily precipitated out especially when inadmixture with other wastewatersTreatThe dstrateSolidsMostsolidsdensitfiltratusedOils aThe ALaw totment odifferenegies tos removsolids cs recoveties clotion orusing a

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

and greAPI sepo definof indusnt typeso removvalcan beered asose to tultrafialum salease rearatore the rstrial ws of conve the cremoveslurryhe densltrationts or themovalis a grarise velowastewantaminacontamed usingor sludsity ofn may bhe addiAPI oiavity seocity ofateration ofinationg simpledge Ver

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

water pbe requition ofil-wateeparatiof oil drof wastee sedimery finepose spired Alpolyeleer sepaon devicoplets bewater rentatiosolids aecial prlthoughectrolytratorce desigbased orequiren technand soliroblemsh floccutesgned byn theira varieniques wds withs In suulationy usingdensityety ofwith the

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

hch casemay beStokesy andeeesize Tand thspecifsuspethe oimiddleTypicadisposscrapfurthaddititreatmA typParalltiltedsepardropleresulta convRemovThe deshe wastfic gravended soil risese layerally thsed ofer (or ser treaional rement unical parel plate

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

d paralleation)ets to ct is thatventionaval ofsign is btewatervity diffolids seto topbetweee oil layand thesimilaratmentemoval onit forrallel ple separael plateThe pacoalescet a paraal API sbiodegrbased or becauferenceettles toof theen the oyer is se bottodevice)consistof any rremovaate sepators aassembrallel p

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

e into laallel plaseparatradableon the sse thate betweo the bseparatoil layekimmedom sedi) and a sting usuresiduaal of undparatorre simiblies (tlates prarger gate sepator to ae organspecifict differeen thebottom otor andr and thd off anment lasludge pually ofl oil anddesirablar to Ao enhanrovide mglobulesarator rachieve

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

nicsc gravitrence ise suspenof the sd the clehe solidnd subsayer is rpump Ta Electd then tble dissoAPI sepnce themore sus Howerequirethe samty diffes much snded soseparateansedds[3]

equentremoveThe wattro-flotto someolved cparatorse degreeurfacever thees signifme degerence bsmallerolids andtor as awastew

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

ly re-prd by a cter layetation me type ohemicas but the of oilforsuse parallficantlyree ofbetweer than td watersedimewater isrocessechain aner is senmodule fof biolol compohey incl-waterspendedlel platey less spseparatn the other Theent layes theed ornd flighnt toforogicaloundsluded oil

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

es Thepace thtionilerhtehanBiodetreatactivaexcesneat bpesticproceActivaActivawasteoxidizoxidizTrickA schtricklgradabusing eated slussively dblood orcides oessesvated slated sluewater tze organzed matkling filematicing filtle orgaextendeudge ordiluted

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

r milk Tor antibludge pudge isthat usnic pollterialter procross-sernic mated convtricklinwith waThe preiotics cprocessa biochses air (utantsocesssectionterial ofentionang filteashingesencecan haveshemicalor oxygproducn of thef plantal wasteer Probwater oof cleae detrimprocesgen) ancing a w

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

e contacor animewaterblems caor is higaning agmentalss for td microwaste slct facemal origtreatman ariseghly congents dimpacttreatingoorganisudge (oof thein is usument proe if thencentraisinfecs on treg sewagsms toor floc)bed meually poocesseswastewated suctantseatmenge and inbiologiccontainedia in aossible t

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

s such awater isch asntndustricallyning thetoassialeA typA tricplasti(or filmaintair Tby thethe oxThe ethe oxpenetTreatSynthpesticTreatMethovitrifSomedegrabe useTreatAcidsNeutras a sevolvetreatmical comckling fc medialm) of m

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

ained bhe proce microxygen rend prodxidationtrate thtment ohetic orcides ctment mods incicationmateriadationedtment os and alkralisatioolid resed requment armplete tfilter coa over wmicrobiby forcecess invobial slimrequiredducts inn As thhe layerof otherganic mcoking pmethodsclude A incineials sucand in sof acids

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

kalis caon freqsidue thuiring trre usuatricklinonsistswhich wal slimeed air fvolves ame layed for thnclude che slimer and aner organmateriaproducts are ofdvanceerationh as sosuch cas and aan usualquentlyhat mayreatmenlly requng filterof a bewastewae coveriflowingadsorpter diffuhe bioccarbone layern innernics

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

ls includs and sften sped Oxid chemme detases a malkalisly be neproducy also bnt for tuired for systemed of roater floing thethroughion of ousion ofhemicadioxidethickenanaerobding soo forthecific tdation Pical immtergentsmodifieeutralises a prebe toxicthe gasollowingmocks grows dowbed meh the borganic

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

f air intl oxidate gas wns it bebic layelventsh can beto the mProcessmobilisas may bed formsed undecipitatc In somstreamg neutraravel slwnwardedia Aebed or bcompouto the stion ofwater anecomeser is forpaintse very dmateriaing disation obe capam of wasder contte thatme casem Somealisationlag peaand conerobic c

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

by naturunds inslime lathe orgnd othedifficurmedpharmdifficultal beingstillatior landfble of bstewatetrolledwill reqes gasse othernat mossntacts aconditioral convthe waayer toganic coer produult for taceutict to tretreateon adsfill dispbiologicer treatconditiquire trses mayforms orlayerons are

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

vectionastewatprovideompounducts ofthe aircalseatdsorptionposalcaltment consreatmey beofoferedstoncanntWaste streams rich in hardness ions as from de-ionisation processes canreadily lose the hardness ions in a buildup of precipitated calcium andmagnesium salts This precipitation process can cause severe furring of pipesand can in extreme cases cause the blockage of disposal pipesTreatment isby concentration of de-ionisation waste waters and disposal to landfill or bycareful pH management of the released wastewaterTreatment of toxic materialsToxic materials including many organic materials metals (such as zinc silvercadmium thallium etc) acids alkalis non-metallic elements (such as arsenic

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

or selenium) are generally resistant to biological processes unless verydilute Metals can often be precipitated out by changing the pH or bytreatment with other chemicals Many however are resistant to treatmentor mitigation and may require concentration followed by landfilling orrecycling Dissolved organics can be incinerated within the wastewater byAdvanced Oxidation Processes

Quality ControlModernization and Infrastructure DevelopmentModernization and Renovation of Quality Control Laboratory is underprogress A new laboratory building is under construction and the oldlaboratory building is being renovated phase wise For smooth commissioningand operation of MSQ project and other test facilities a new laboratory isbeing set up Carbon Nitrogen Sulphur amp Chloride Analyser This instrument iscapable to check these elements in sub ppm level in different petroleumproducts This is a microprocessor based automatic instrument GC Oxygenates This special type of Gas Chromatograph is used to checkoxygenates content in gasoline This parameter is required to be testedto certify BSIII MS Potentiometric Titration System It is used for evaluation of Dienecontent (MAV) Bromine number Bromine index etc in petroleumproducts RON Engine An advance model RON engine is under final stage ofprocurementarrivalDevelopmental Studies

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Viscosity grade Bitumen BIS introduced new Specifications for Bitumen(IS 732006) implemented where some new specification parameters likeviscosity at different temperature and vacuum were incorporated Testfacilities for these new parameters were developed Antioxidant Dose Optimization Study To optimize the dosing rate ofanti oxidant in MS blending component ex-FCCU a study was conductedEffectiveness optimum dosing quantity reaction time of antioxidant wasdetermined and informed to production for implementation BS III HSD Certification Till date HSD produced in BR is certifiedunder BSII specification Test facilities have been developed to certifyHSD under BSIII specification Few batches of BSIII HSD have alreadybeen certifiedBS III MS Certification Test facility has been developed for carryingout additional test required for certification of BSIII MS BSIII MS Production Blend study for production of BSIII MS beforeMSQ commissioning with imported isomerate amp MTBE CLO up-gradation CLO is a low demand low value stream ex-FCCU Ithas certain disadvantages like high viscosity high density high ash etcBlend study was conducted to find out the possibility of using CLO as FOblending component IFO up-gradation amp Certification of FO To find the possibility ofselling IFO as Fuel Oil samples from all IFO tanks were collected andtested for all Fuel Oil parameters Certification of FO a new product isdone wef April 2009 Trial runs conducted to assess FOIFO quality

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser

Further blend study and optimization of PPD doses were done to meetcertification of winter grade FO ATF Production ATF produced from different crude mix was found to befailing in Acid number and JEFTOT test Study was conducted to reduceacid number by caustic wash followed by water wash Commissioning of DHDT 3rd Reactor Laboratory support was given byway of continuous product quality evaluation for commissioning of DHDT3rd reactor DHDT PGTR For performance evaluation Quality of all rundown streamswas evaluated during DHDT PGTRLoss Control(I)Quality Give Away (QGA) Prevention To generate awareness among allconcerned QGA value in terms of money was calculated for all certifiedtanks and circulated Significant improvement has taken place in this field(II)Portable Flue Gas Analyser Two portable Flue Gas Analysers wereprocured and put in service for in-situ analysis of flue gas to improvefurnace efficiency(III)LPG Loss Control Fuel gas was checked on regular basis for LPGslippageEnvironmental Management Effluent Quality Monitoring under new MINAS Monitoring of Raw water and drinking QualityCost Reduction in Utility Consumption Use of hydrogen amp nitrogen generator in place of cylinders Use of Orsat apparatus in place of dragger tube for checking H2Scontent Use of low cost Argon in place of Helium for operation of low levelSulphur and chloride analyser