Report Priyanka

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Summer Training

Report On

Atmospheric and

Vaccum Unit

(From 17th June 2013 to 12th July 2013)

Submitted By:

Priyanka Singh

B.tech (3rd year ),

Chemical Engg.

Anand Engg. College,

Agra


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Acknowledgement

I am very thankful to all those honorable people who were involved in guiding me throughout my

venture as it was their valuable experience and knowledge that I was able to complete my

training with ease and satisfaction.

I would like to express sincere gratitude to my Institute, Anand Engg. College,Agra and

Indian Oil Corporation, which provided me with an opportunity to achieve my goal.

I am thankful to Mr. Kuldeep Kumar Baldia, Officer(T&D), Mathura Refinery who believed

in our ability and allowed us to undergo vocational training in Mathura Refinery.

My heartfelt thanks to Mr. Pramod Kumar , Chief Production Manager, Mathura Refineryfor their proper guidance throughout my training.

I also express my sincere and heartfelt thanks to Mr. Samiullah, (Mgr.VBU), Mr.A.K.Gautam

(Mgr. AVU) , Mathura Refinery for their dedicated guidance, constant encouragement and

valuable time throughout the training duration.

The assistance and moral encouragement received from my family is gratefully acknowledged.


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Purpose of vocational training

As per the All India Council of Technical Education (AICTE), a governing body for technica

education in India, norms B-Tech (Bachelor of Technology) is a professional course which

comprises of four years of study of the various Engineering subjects of the particular discipline

In theory, we learn about various machines without knowing them actually i.e. we can only knowhow the parts of machines functions. But when it comes for identifying of machines we remain a

the back foot. Further, the processes, mechanisms, which we are studying are of conventiona

nature, i.e. these are the basics to do a particular thing, produce items, etc. Due to increased

demand, calling of better product quality, the industries have adopted unconventional type o

processes to which we are not familiar. So, in order to visualize a thing in complex productio

system, we need to go through he basics of an industry, their way of working, identification o

equipment by just looking, etc.

Thus the purpose of vocational training is to:

Identify the equipment by just looking at them.

To know about the working of critical equipments.

To understand the working of equipments which we have already studied or yet to study.

Be familiar with the system, production, maintenance, inspection e.t.c.

Know how the basics are utilized to manipulate the production processes & system along

with the equipments.

The purpose of vocational training is NOT the mastering of whole system since it is very

difficult to know each & every thing about a particular industry & its complex processes.


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S. No Name of topic Page No.

1. Introduction 1

2. Historical Overview 33. Description of Mathura Refinery 4

4. Fire and Safety 5

5. Block Diagram of refinery 6

6. Glossary of commonly used words 7

7. Old Unit

Purpose and description of Old Unit

Structure of Old Unit

Process Flow Chart of Old Unit

Atmospheric & Vacuum Distillation Unit (AVU)

Vis-breaker Unit (VBU)

Continuous Catalytic Reforming Unit (CCRU)

Fluid Catalytic cracking Unit (FCCU)

Merox Unit

9 - 27

9

10

11

18

21

24

27


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INTRODUCTION

Refinery is a plant that basically refines the crude oil into the various kinds of petroleum product

(finished).The crude oil is the raw material foe this plant and it is purchased from the othe

countries and from the parts in our country as well.

The crude oil in Mathura Refinery comes from Bombay High which is th

chief source of crude oil in the Indian subcontinent. It is transported from there to Okha (the

outermost part of India near the sea in Gujarat) by ships. It is then stirred in tanks which are

located in that re region. This crude oil is then transported from Salaya (village in Okha) t

Mathura Refinery by means of Salaya-Mathura Pipeline. This work is undertaken by pipelin

departments.

Thus Indian Oil Corporation Limited (abbreviated as IOCL)

Is basically a joint collaboration of Refinery & pipelines. The Refinery is totally concerned

with this production, marketing of petroleum products while the pipeline department has nothing

to do with the production departments & is involved in transportation of crude oil.


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Historical Overview

IOCL has been a largest producer of petroleum products fromcrude oil & is public sector government undertakin

organization. In the past, where there were only thee majo

producers of petroleum products in namely IOCL, BPCL &

HPCL. The IOCL alone had a credit of producing about 70% o

the total consumption while BPCL about 28% at that time. Then

at that time quality was not so important for the IOCL as th

consumers has to buy the products either it is good or bad due to

non-availability of other sources. Further, there was n

competition in this sector and the primary motive was to produc

more & more without bothering the quality.

But, as the time changed, the private sector had

also come into existence thus increasing the competition in th

market.eg Reliance Oil Refinery. This called for better produc

quality at a considerable low cost. Now, in order to maintain it

existence in the market, IOCL had undergone several changes to ensure better quality. They had

spent a lot of money in installing highly modern plants equipped with world class machinery.

They are trying to stick to the prescribed quality standards and have maintained

various departments e.g., Inspection dept., fire & safety dept., Inventory & materials dept., etc

Today, IOCL is the major producer of petroleum products in India.


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Mathura Refinery is an ISO: 9001 Organization and isinvolved in refining of crude oil into various forms of

useful petroleum products. It is spreaded over an area of

about 40sq.km and is well connected by means of rail &

road. It is built under the No Flying Zone. It is among th

top 100 Oil refineries in the world.

Crude being processed at mathura refinery are as

follows:

1. Low sulphur crudes : Indian (Bombay high)Nigerian (Qua Iboe)

2. High sulphur crudes : Saudi Arabian,Arab medium

The crude oil is supplied to Mathura Refinery by Salaya

Mathura Pipeline from Okha, to where it comes from

Bombay High by means of ships. This after bein

converted into petroleum products is sent into different regions of the country. It distributes on it

own in U.P & other adjacent states. One distribution station is at Bharatpur & other a

Jalandhar.The oil to Jalandhar is transported through pipeline known as MJPL pipeline (Mathura

Jalandhar Pipeline).This distribution is also made through the Railways. Mathura Refinery also

owns a residential colony for its workers as Mathura refinery Nagar. It is located at distance o

5km towards Mathura from the Mathura Refinery, both being on the NH-2(Agra-Delh

Highway).Mathura Refinery Nagar has a lush green sprawling area.


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Block Diagram of Refinery.


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Glossary of commonly used words.

CDU Crude Distillation Unit.

LPG Liquefied Petroleum Gas

SKO Super Kerosene Oil

ATF Air Turbine Fuel

FO Furnace Oil

LDO Light Diesel Oil

HSD High Speed Diesel

MS Motor Spirit / Petrol / GasolineDCU Delayed coking Unit

HCU Hydrogen Cracking Unit

FCCU Fluidized Catalytic-Cracking

Process

VBU Vis Breaking Unit

RPC Refined Petroleum Coke

SRU Sulphur Recovery Unit

BTU Bitumen treating UnitPRU Propylene Recovery Unit

AU Atmospheric Unit

AVU Atmospheric Vacuum Unit

VDU Vacuum Distillation Unit

VGO Vacuum Gaseous Oil

RCO Residuum Crude Oil

CRU Catalytic Reforming Unit

LLDPE Linear Low Density

Polyethylene

HDPE High Density Polyethylene,


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Key

1. AVU- Atmospheric Vacuum Unit

2. VDU- Vacuum Distillation Unit

3. CDU- Crude Distillation Unit

4. CCRU- Continuous Catalyst Reformer Unit

5. FCCU- Fluidized Catalyst Cracking Unit6. PRU- Propylene Reformer Unit

7. VBU- Viscosity Breaker Unit

8. MEROX- For The Recovery Of LPG

9. BITUMIN UNIT- For The Recovery Of Bitumen (Coal-Tar)


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Key

1. HN- Heavy Naphtha

2. ATF- Aviation Turbine Fuel

3. HK- Heavy Kerosene

4. LGO- Light Gas Oil

5. HGO- Heavy Gas Oil

6. RCO- Residual Crude Oil7. LVGO- Light Vacuum Gas Oil

8. LDO- Light Diesel Oil

9. HVGO- Heavy Vacuum Gas Oil


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ATMOSPHERIC & VACUUM DISTILLATION UNIT (AVU)

PROCESS FLOW DESCRIPTION:

Atmospheric Distillation Process.

1. FEED SUPPLY:

Crude oil is stored in 8 tanks .Two tanks are having a capacity of 65000 m 3 & other six tanks ar

having a capacity of 50000 m3 each respectively. Booster pumps located in the off site area wil

take suction from any one tank & deliver into the suction unit feed pumps. Normally three of the

four pumps are working.

2. FEED PREHEAT TRAIN-1:

The crude feed pump charges crude oil into desalter through a series of shell & tube exchanger

in the preheat train where it is heated to the desalter temperature. Crude oil in train-1 i

distributed into three parallel streams & passes through the exchangers where it is heated by the

product streams on the shell side. Then the three streams combine to give an average temperatur

of the feed.


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3. DESALTER:

The desalter is an electrostatic coaleser to purify the crude from sediments & corrosion inducing

salts & thereby reduce fouling & corrosion of the distillation equipments. Sediments contain fin

particles of sand, clay, rust etc. salt are generally sodium, magnesium, calcium & chlorides. Som

traces of carbonates & sulphates are also present. Desalter pressure is maintained at 11-12kg/cm2.Small quantity of water is added in the desalter. A high voltage is applied so tha

ionisation of the salts takes place & they get dissolved in the water. Sediments also settle down &

are removed with the brine. The brine is cooled in the air & water coolers before final disposal.

4. CRUDE PREHEAT TRAIN-2:

Desalted crude is pumped through a series of heat exchangers (shell & tube type) where it i

heated to the pre fractionator temperature by the products in the shell side. Crude in the preheatrain-2 is divided into three parallel streams where it get heated in a series of exchangers &

finally combines to give a average stream temperature of 180 C-190C. The combined stream i

fed to the pre fractionator.

5. PRE FRACTIONATOR:

The pre fractionator column is provided to unload the load on the crude charge heater as well a

the crude column. The IBP-100C-110C cut naphtha is recovered from the crude oil in the pr

fractionator column as the overhead product where as the bottom product is sent for furthe

processing. Thus the pre fractionator helps in increasing the capacity of the plant & helps insaving energy. Medium pressure steam is sent in the column to strip of the lighter products &

which helps in carrying the lighter end products.

Column temperature:

Bottom : 174 C-180 C

Top : 114 C-120 C

Column pressure:

Bottom : 2.2-2.8 kg/cm

2

Top : 1.8-2.4 kg/cm2

The overhead products are condensed in air & water coolers & collected in the reflux drum.A

part of the collected product is sent as reflux & rest is sent to the stabilizer. Heavy naphtha is also

sent to the stabiliser from the atmospheric column. The stabilised naphtha is sent as feed to the

CCRU.


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6. CRUDE PRE HEAT TRAIN-3:

The bottom product of the pre fractionator is pumped into the train-3.The stream is split into thre

streams with the help of flow controllers & passes into a series of heat exchangers where it is pr

heated before entering the furnace. The stream combines before entering the furnace to give a

average stream temperature of around 250 C

7. CRUDE FIRED HEATERS:

The furnace used in the AVU is a balanced draft furnace. The preheated crude is further heated &

partially vaporised in the four no. of parallel tubular heaters. Each heater is a box type vertica

furnace with up-firing burners (14 no. in each furnace) provided on the floor with processing fue

oil & fuel gas firing. Crude is passed in each furnace in four passes provided with control valveat the crude oil inlet to heater coils.

Like the other conventional heaters, this furnace also has two zones (i) convection zone &

(ii) Radiation zone. There are eight rows each having eight tube in the convection zone. There ar

eighty four tubes arranged vertically in the radiation zone with twenty one tubes from each pass

The feed enters the convection zone, gets heated by the flue gases. Then it passes into th

radiation zone for further heating. The maximum skin temperature goes up to 550C.The fue

entering is atomized using medium pressure steam for better burning of the fuel. The air provide

for burning is preheated using the flue gases, thus saving heat.

8. CRUDE DISTILLATION SECTION:

Crude oil stream combines at the outlet of the furnaces into one stream & enters the flash zone o

the column. The atmospheric column is divided into three sections. The column height is abou

67 metres. The top & bottom section of the column is about 5.5 metres in diameter& middle

portion is 6.4 metres in diameter. The trays in the column are replaced by the packed bed t

increase the contact time of vapours. To insure complete recovery of the lighter hydrocarbons th

bottom of the tower is charged with superheated medium pressure steam produced in the furnaceThe feed enters at a temperature of around 350 C.

Gasoline/light naphtha vapours & water vapours are withdrawn from the top of the column

passes through the air coolers & the condensate gets collected in the reflux drum. Water i

drained from the bottom. Apart of the reflux is sent to the column as reflux to maintain th

temperature & rest is routed for the removal of H2S& mercaptans in other units.


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Heavy Naphtha cut is withdrawn from the fourth tray enters the stripper. Superheated steam i

introduced at the bottom of the stripper which helps in removing the lighter products coming with

it. The stripped off vapours re-enter the column. The bottom of the stripper is then pumped by th

pump via heat exchangers & air coolers to the run-down diesel, naphtha from the stabilizer or t

the storage tanks.

ATF is withdrawn from the chimney tray below the ATF packing is sent to the side stripperSuperheated stripping steam is provided to strip of the light vapours which re enter the column

above the packing & bottom of the stripper is pumped via heat exchangers & air coolers to th

storage tanks. Apart of the ATF is provided as the circulating reflux to maintain the temperature

& reduce the vapour load.

Heavy kerosene is withdrawn from the HK packing & sent to the side stripper. The stripped

kerosene is pumped via pumps through the heat exchangers & air coolers to the coaleser to

remove the water. The kerosene from the coaleser is sent to the storage tanks. The vapours from

the stripper enter the column at the top of the packing. A reflux stream is also provided tomaintain the column temperature.

Light Gas oil (LGO) is withdrawn below the LGO packing & enters the stripper. The stripped of

vapours enter the column above the packing & the bottom is pumped via pumps through a serie

of heat exchangers & air coolers to the coaleser which helps in removing the water. The LGO

from the top of the coaleser is sent to the HSD storage with the other diesel component A

circulating reflux is also provided to maintain the column temperature.

Heavy gas oil (HGO) is withdrawn below the HGO packing & enters the stripper. The stripped

off vapours enter the column & bottom is sent via pumps through the heat exchangers to thstorage tanks. Reflux stream is also provided in the same way.

The residue left in the column bottom known as the atmospheric residue is sent as feed to th

vacuum distillation unit.


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10. VACUUM DISTILLATION SECTION:

Vacuum Distillation Process

The feed to the vacuum column is the atmospheric residue. It enters the column at a temperatur

of 350 C after being heated in the vacuum fired heater. The operating pressure is about 60-64

mm of Hg at the top of the column & 90-94 mm of Hg at the bottom. The feed rate to the column

must not exceed 575 m3//h. Vacuum is maintained in the column to reduce the boiling point othe products.

Water vapour & a small amount of lighter hydrocarbons produced by cracking are sent to the top

of the vacuum tower & condensed in the overhead condensers.

The first side cut Light vacuum gas oil (LVGO cut


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part of it is sent to the column reflux & rest is sent to the run down tanks which is further used a

feed for the FCCU.

The left over is the vacuum residue. A part of it is sent as bitumen feed & rest is sent as feed to

the vis-breaker unit.

10. STABILISATION SECTION:

Gasoline from the stabiliser feed accumulator is transferred by pumps through a series of hea

exchangers to the stabiliser column having 37 trays. The overhead vapours is mainly LPG are

condensed in air coolers & collected in the reflux drum.A part is sent as reflux to the column top

& rest is routed to the merox unit. The stabilised gasoline from the column bottom is sent as feed

to the CRU.

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