INDIAN OIL CORPORATION

Propelled by a sense of determination fueled, fueled by a spirit of innovation

the effort of thousands of dedicated Indians wrote a glorious, new chapter on
the Indian oil story.
Only three decades ago, Indian looked to the world for help in its quest for
oil. Then slowly, but surely the scenario changed. Indian oil corporation
ltd.(Estd.1958) with Indian oil company(Estd.1959)played a leader role in
this transformation.
Today, Indian oil owns and operates 6 refineries at Digboi, Guwahati,
Haldia, Barauni, Mathura and Gujarate amongst the countrys twelve
refineries, with a combined crude oil refining capacity of over 24 million
tones which is about 47% of the total refining capacity in India. Indian oils
seventh grassroots refinery is coming up at Karnal in Haryana with a
capacity of 6 million tones per annum.
Indian oils first product pipeline in the Guwahati-Siliguri sector carned
itself the honors of being the first petroleum product pipeline to be
constructed on the eastern side of suez canal.Indian oils pipeline length
progressively grew to todays level of over 3800 km maintaining an
uninterrupted flow of crude oil to refineries and petroleum products to the
consuming centers across the length and breadth of the country.Currently,
Indian oil is executing its longest ever petroleum product pipeline ,all of
1454 km, originating from Kandla in Gujarat and terminating at Bhatinda in
Punjab.
Whats more, Indian oil reaches a wide spectrum of customers through its
marketing wing .it sells over 32 million tones of petroleum products
annually through a country wide marketing network. Indian oil commands a
market share of about 57% on the whole. it is interesting to note that Indian
oil runs a retail outlet at the worlds highest point kaza in Himalayas as well.
Indian oil is the only oil refining and marketing company in India India
which has a full fledged research and development center. nearly 600 of the
lubricant formulations developed at this center have been commercialized
thereby indegenising over 95% of the lubricant marketed by Indian oil. This
center has mastered the complete know how of FCC catalyst evaluations and
manufacturing in India with its own formulation apart from giving support
services on fccs to Indian refineries.

MATHURA REFINERY
The modern temple : Mathura refinery standing bold on the outskirts of
Mathura on Delhi-Agra highway, has been the harbinger of technological
advancement in this region in perfect harmony with the environment.
Nurturing technology amidst the greens has been a pioneering experiment of
a modern industry and Mathura refinery takes pride in successfully
accomplishing this arduous task since its inception.
A torch bearer of north west India: Mathura refinery has been the focal point
of development in industrial and transportation sector for almost the entire
northwest India since its commissioning in jan.82. This 7.5 million tonne
refinery is indias latest and most modern refinery. Also, it has the wide
adaptability of processing over 30 types of crude oil. This ranges from
indigenous Bombay offshore crude to imported crudes of Australian origin
in the east and Nigeria and Venezuela in the far west. Mathura refinery has
the distinction of having single largest capacity crude distillation unit which
has the unique engineering marvel of 67 m high crude distillation column.
the crude to the refinery is received from salary in west coast through a
dedicated cross country 1078km pipeline . Products from this refinery are
dispatched through rail, road and Mathura-Delhi-Ambala-Jalandhar pipeline
.the contribution of Mathura refinery in meeting the petroleum products
demand of north west India is about 68%. The LPG bottling plant situated
with in Mathura refinery premises bottles nearly 7 million cylinders per
annum for catering to domestic market. Major fertilizes industries at
Kanpur,Panipat, Nangal, Bhatinda and Kota are supplied with naphtha or
furnace oil/ heavy petroleum stock as fertilizer feed stocks from Mathura
refinery. Also, thermal power plants of Nangal, Obra and Badarpur get fuel
oil supply from this refinery. Apart from this, Mathura refinery is privileged
to provide the necessary energy to the pulsating capital, New Delhi and also
boost the standards of the farmers belonging to the crop rich lands of Punjab
and Haryana.
The other important product, bitumen, has paved the transportation sector in
this region on to road worthiness. To keep the environment clean and
green.Mathura refinery recovers nearly 10,000kgs of sulphur everyday as a
by-product from crude oil.

PRODUCTS AND THEIR SPECIFICATION

The following petroleum products are obtained from crude oil in Mathura
refinery,
1. Liquidified petroleum gas
2. Motor sprit or petrol
3. Naphtha
4. Aviation turbine fuel
5. Kerosene oil
6. High speed diesel oil
7. Light diesel oil
8. Fertilizer feed stock
9. Heavy petroleum stock
10. Bitumen
11. Sulphur

PRODUCT SPECIFICATION:
L.P.G:
1. Copper corrosion at 38C for one hour.
2. Total volatile sulphur = 0.02%max
3. Vapour pressure at 65C = 16.87C Kg/cm gauge.
4. Hydrogen sulfide = absent.
5. Dryness =no free entrained water.
6. Weathering test =83C
MOTOR GASOLINE:
1. Colour usually orange
2. Copper strip corrosion for 3 hrs at 50C.
3. Octane number = 88RON, 93RON
4. Residue on evaporation = 4mg/100m.
5. Sulphur total =0.25wt%
6. Vapour pressure at 38C = 0.70Kg/cm
7. Flash point = below 25C.
ATF:
1.
2.
3.
4.

Appearance =usually clear and bright free from.

Flash point = 38C
Freezing point = -50C
Smoke point = 20 mm max.

ATMOSPHEREIC AND VACUUM UNIT

The crude distillation unit was designed for desalting and primary
distillation of light Arabian crude and North Rumalia mixture in the
proportion of 1:1.
The nominal designed capacity of the unit was 6MMTPA of the above crude
on mixture. However the designed provided a possibility of processing
7MMTPA of crude of containing 2% weight of gas. Process calculation,
sizing of vessels and equipment was made for the same.
The unit has been revamped in different stages to raise its capacity and to
process different types of crude including indigenous crude from Bombay
High. Subsequent to these revamps, the nominal capacity of the unit stands
at 8 MMTPA for processing imported Middle East crude and 7MMTPA for
processing Bombay High. Based on 50:50 processing of imported and BH
crudes in blocked out operation, the nominal capacity of the unit stands at
7.5 MMTPA.
The unit has been designed to produce the following cuts:
LPG
To be sent to Merox treating unit
Naphtha component
C5 140 C
To be used as ATF after Merox
140-250C
treatment
To be used as superior kerosene after
140-270 C
Merox treatment
Light gas oil (HSD component)
250(270)-320 C
Heavy gas oil (HSD component)
320-380 C
Light Vacuum gas oil to be used as
< 380 C
HSD component or as LDO
LDO to be used as LDO component
380-425 C
or FCCU feedstock
FCCU feedstock
425-530 C
Vacuum slops
To be blended into finished FO or to
FFS
Hydrocarbon gas
To be sent to refinery fuel gas system
Atmospheric Residue
To be used as VBU feed component
for the internal fuel oil and as a FFS
component
Vacuum Residue
To be used as feed for BBU,VBU, a
component for internal fuel oil and a

FFS component
Crudes being processed in Mathura Refinery:
Low sulphur crudes
High sulphur crudes

Indian
Nigerian
Saudi Arabian
Kuwait
Egypt
Dubai
Abu Dhabi

Bombay High
Qua Iboe
Arab Medium
Burgan, Ahmedi etc.
Gulf of Suez
Dubai Export
Zakum Upper

Stream Days: Number of stream days per year is 345 days for crude
distillation and vacuum section.

DESCRIPTION OF PROCESS FLOW SCHEME:

FEED SUPPLY: crude is stored in eight storage tanks (six having a
nominal capacity of 50,000 m3 each and remaining two are of 65,000m3
each). Booster pumps located in the off-sites are used to deliver crude to the
unit feed pumps. Filters are installed on the suction manifold of crude pumps
to trap foreign matter. For processing slop, pumps are located in the off site
area which regulate the quantity of slop into the crude header after filters.
Provision to inject proportioned quantity of demulsifier into the unit crude
pumps suction header with the help of dosing pump is available.
FEED PREHEAT (PRE-DESALTER) CIRCUIT: Crude oil from feed
pumps is charged to heat exchangers in two parallel streams.
DESALTING: Desalting is a purifying process used for the removal of
salts, inorganic particles and residual water from crude oil and thereby
reducing corrosion and fouling of equipments. These impurities are brought
along with the residual water content of the crude oil. Water drops ordinarily
are so small that simple gravity settling is very poor .in an oil pool, the
molecules that are least similar to the bulk of oil are subjected to less
intermolecular forces. Being less attracted to the inner body of the oil, the
exceptional material will be rejected to an inter-face of the oil/water drops.
Such rejected surface active materials comprise a physical barrier that
prevents water drops from getting close enough to bring about coalesce.
Before the drops can coalesce the stabilizer film must be reduced in
thickness, tenacity and therefore ruptured.

The electric field is a powerful tool for overcoming the resistance of

stabilizing films. The collision and coalescence of drops is accomplished by
an induced dipole attraction between them. As the droplets then approach
each other, the force between them becomes very great. The stabilizing films
are squeezed between the drops and coalescence is rapid. The large water
droplets produced fall through the oil phase at a faster rate. This desalting
process consists of three main stages, viz. heating, mixing and settling.
Crude oil is heated to 125-135 C in the pre-desalter heat exchanger train.
Water is injected under flow control upstream of mixing valves. Provision is
given at crude pumps suction also to facilitate break-up of tightly bound oilwater emulsion. Brine outlet from the desalters is cooled in air cooler and
water cooler before final disposal. Desalter pressure is controlled between
11-12 kg-12 kg/cm2 by a conyrol valve located at the discharge end of the
crude feed pumps.
POST DESALTER CRUDE PREHEATING: Desalted crude from
desalter is pumped by post desalter pumps into streams going through a
second train (two in parallel) of heat exchangers. Downstream of the
exchangers trains, crude oil streams combine to average out the temperature.
Normal preheat temperature is in the range of 230-250 C.
FIRED HEATERS: the preheated crude is further heated and partially
vaporized in three parallel tubular heaters. Each furnace is four pass heater
with air preheater. Each furnace is provided with 14 burners capable of
firing FO and FG, either fully or partially. Convection section has 8 rows of
tubes with 8 tubes in each row. Two rows of shock tubes just above the
radiant section are plain tubes with out studs. In the convection section 4
studded tubes are for the service of superheating MP stream for strippers.
The radiant box has 21 tubes in each pass. Convection zone had 12 rotary
and 12 retractable soot blowers in two rows.
AIR PREHEATER SECTION: To recover waste heat from flue gases of
CDU and VDU furnaces four identical parallel stationary air preheater units
are provided and installed in parallel. At APH cold combustion air will pick
up heat flue gas poat tobeme routed to the burner could to the burners for
efficient combustion. Three FD fans each capable of 55% of full load are
provided with SCAPH in there discharge to heat the air unto 45 C. the
combustion air requirement of each heater is controlled by individual FICS
damper located in the air duct to the respective furnace. Load on the fans is
varied by regulating the inlet guide vances. Heaters are provided with slain
temp O2 analyzer and draft gauges.
Furnaces are provided with different trip logic to save the equipments under
different abnormalities.

CORROSION INHIBITOR: A solution of corrosion inhibitor in light

hydrocarbon is required to be properly dispersed in vapor stream to combat
corrosion of the overhead system. Most of the inhibitor is active in specific
ranges closes to neutral.
DEMULSIFIER: the injection rate should be around 6-8 ppm on crude.

GENERAL:
Corrosion inhibitor drums
Ammonia cylinders
Demulsifier drums

165 kg/drum
60 kg/cylinder
185 kg/drum

VISBREAKER UNIT
The visbreaker unit is designed for processing a mixture a mixture of
atmospheric and vacuum residue from 1:1 mixture of light Arabian and
north Rumalia crudes. It reduces the viscosity and pour point of heavy
petroleum fractions so that product can be sold as fuel oil. The capacity of
the plant is 0.8 1.0 MMTPA of mixed feed. Products of this unit are LPG,
Gasoline, gas oil and VB tar.

THEORY OF VISBREAKING:
The visbreaker is essentially a thermal cracking unit designed to operate at
mild conditions and to retain all the cracked light oils in the bottom product.
In the thermal cracking reaction heavy oil is kept at a high temperature for a
certain amount of time and this causes the larger molecules to breakup. The
resulting product has a random distribution of molecular sizes resulting in
products ranging from light gas to heavy gas oil. Whenever a molecule
breaks up one of the resulting molecules is an olefin.
CH3CH2CH2CH2CH2CH2CH3 CH3CH2CH=CH2 + CH3CH2CH3
Cracked products are unstable and form gum. During the cracking operation,
some coke is usually formed. Coke is the end product of polymerization
reaction in which two large olefinic molecules combine to form an even
larger olefinic molecule.
C10H21CH=CH2 + CH2=CHC10H21 C10H21CH=CHCH2CH2C10H21

When the above reaction gets repeated several times the end product is coke.
Severity of overall reaction is determined by residence time and temperature
of cracking.

PROCESS FLOW DESCRIPTION:

General: the feed stock form AVU is received in the surge drum. Pumps
take suction from the drum and discharges through a set of preheat
exchangers into two furnaces operating in parallel. Each furnace has two
passes and provided heat required for preheating and cracking reaction of
feed under controlled conditions. The furnace effluent is sent to a soaker for
further cracking. The residence time in the soaker is as large as 30 minutes.
Soaker effluent is quenched by injecting cooled VB tar to arrest further
cracking. There is also provision of processing slop in the unit.
The quenched effluent enters the main fractionators where gas and gasoline
are withdrawn as overhead, heavy naphtha and gas oil as side streams and
VB tar as bottom. The over from the fractionators are cooled and condensed.
The gas goes to FCC and the gasoline is partly refluxed and the rest sent to
stabilizer. The stabilized gasoline is sent to naphtha Merox unit for sulphur
removal.
The heavy naphtha drawn is steam stripped in heavy naphtha stripper. It is
then cooled and mixed with MGO and LDO.
The gas oil is drawn from the pan of the tower and is steam stripped in the
stripper to meet flash point specification. It is cooled in air cooler and mixed
with VB tar leaving the unit or can be routed HSD pool. The VB tar from the
main column bottom flows into tar stripper where gas oil fractions are
evaporated as a result of pressure reduction. The tar after cooling is partly
sent to the bottom of flash fractionators, tar stripper, heat transfer lines such
as quench and the rest goes to storage tank after further cooling by either
mixing with oil or alone.
FEED SUPPLY AND PREHEATING: the unit feed is normally supplied
from tank to feed surge drum at a temperature of 90C and during prolonged
run of imported crude, from AVU at 150C. From the surge drum, the feed
is pumped successively via feed /VB tar exchangers where feed is heated
from 125 - 335C and VB tar is cooled 351 - 257C.
VISBREAKER FURNACES: VBU is provided with two identical natural
draft furnaces. They are upright steel structures with outer steel casing lined
with refractory material. Each of the furnaces has a radiation section at the
bottom, convection section above it and stack at the top. The convection

section is provided to increase thermal efficiency of the furnace by removing

further heat from the flue gases leaving the radiation section. It is having
steam superheater tubes, steam-generating tubes and oil tubes each of these
numbering 6,10 and 14 respectively. The radiation section houses the
radiation tubes numbering 30 in each pass. In this section heat is transferred
primarily by radiation by flame and hot combustible gases. The maximum
allowed tubes skin and box temperature in the heaters are 650C and 750C
respectively. Boiler feed water is circulated through steam generating coils
to recover heat from the flue gas.
Feed from exchangers is supplied to furnaces in two parallel streams at a
pressure of 17.6 kg /cm2. Each furnace has got two passes. Flow through
each pass is controlled by flow control valves and feed is heated up to
485C.
The feed is first heated in the convection section and then it passes through
radiant zone coils located in the two compartments of each furnace. Each
compartment has individual firing controls. Combinations of oil and gas
burners have been provided. Return lines are provided on all the four fuel oil
headers of the furnaces. A 1:1 ratio of fuel oil consumption to return is
provided to obtain good control on firing and prevent congealing of the
internal fuel oil system.
Pressure of atomizing steam to burner for all the four passes are controlled
by differential pressure controllers provided in field 1.5 kg /cm2 differential
pressure between fuel oil and atomizing steam is maintained to achieve good
atomization and efficient burning of fuel oil i.e. steam pressure is 1.5 kg/cm2
more than fuel oil pressure.
To arrest cracking reactions, material from each pass of the two furnaces is
individually quenched by the injection of cooled VB tar at 232C. The
quench rate is controlled by flow controller. To increase turbulence and to
prevent coke deposit in the coil, there is provision to inject steam in each
pass.
VB FRACTIONATOR: furnace effluent after quenching enters the
fractionator. Temperature in the flash zone is around 427C. From the
column, gas and gasoline are separated as side stream and the VB tar as
bottoms. The fractionator has 22 valve trays and one blind tray. Feed enters
flash zone below the blind accumulator tray. The overhead vapors from the
column are condensed and cooled. The liquid vapor mixture is separated in
the reflux drum. Gasoline from the reflux drum is picked up by pumps and
partly pumped to column top as reflux. Top temperature is maintained at
about 137C. The remaining gasoline is routed to stabilizer under reflux

drum level controller. The sour water is drained from the drum boot under
interface level controller and routed to sour water stripper. Main reflux drum
and its water boot are having level glasses. Uncondensed gas from the reflux
drum goes to FCC/AVU furnaces/flare. Column top pressure is maintained
at around 3.2 kg/cm2. Column overhead line is provided with working and
controlled safety valves. Stabilizer reflux pump takes suction from the drum
and discharges it to column top as reflux. Drum is provided with a boot from
where is routed to sour water stripper. Stabilizer bottom temperature is
maintained about 180C.in the reboiler, gas oil circulating reflux is cooled
from 327-260C. Stabilizer bottom goes out by its own pressure to
exchanger where it cools down from 180 - 120C. Then it is further cooled
to 40C in water cooler. Stabilized gasoline is routed to Merox unit for
sulphur removal.

FLUDISED CATALYTIC CRACKING UNIT

INTRODUCTION: the unit is designed for use of high alumina micro
spherical synthetic catalyst as fresh catalyst. At start up, rather than charging
fresh catalyst, which is very active used catalyst, which is less active and
which represents equilibrium condition when unit is in normal operation is
charged to the unit as initial inventory. This type of catalyst is known as
equilibrium catalyst. Fresh cannot be used for initial charge, as it will
substantially over crack the feed till its activity declines to desired level.
Fresh catalyst is used only as makeup for making up losses as well as to
maintain catalyst activity to the desired level. It is preferred that metal factor
be as low as reasonably possible. Also catalyst coke should be minimum in
order to prevent high temperature at start up.
There are the two types of catalyst;
1.fresh catalyst (High alumina microspherical synthetic catalyst).
2.Equilibrium catalyst.
FRESH CATALYST:

UOP
TEST

Apparent Particle Pore

Chemical Volatile Fe
bulk
size
volume and
matter
Wt%
density
analysis ml/gm impurity
level
255-65
422-63 425-63
408-71 34030

NaO SO4 Al2 O3

Wt% Wt% Wt%

41072

74273

25663

METHOD
SPEC.
0.420.02

16max

.04
max

.03
max

.5
max

25
min

PROCESS DESCRIPTION:
CRACKING SECTION: a cracking process uses high temperature to
convert heavy hydrocarbon into more valuable lighter products. This can be
accomplished either thermally or catalytically. The catalytic process has
completely superseded thermal cracking as the catalyst helps the reactions to
take place at lower temperature and pressure. At the same time the process
produces a higher-octane gasoline, more stable cracked gas and less of the
undesirable heavy residual product.
The fluid catalytic cracking process employs a catalyst in the form of minute
spherical particles, which behave like a fluid when aerated with a vapor.
This fluidized catalyst is continuously circulated from the reaction zone to
the regeneration zone also transferring heat with it.
FCCU consists of two sections, the catalyst section and the fractionation
section, which operate together in an integrated manner. The catalyst section
consists of the reactor and regenerator, which together with the standpipes
and riser form the catalyst circulation circuit. The catalyst circulates up the
riser to the reactor, down through the stripper to the regenerator, across to
the regenerator standpipe and back to the riser.
Feed to the FCCU is the gas oils obtained by vacuum distillation of long
residue from the crude distillation unit, the vacuum cut boiling in the range
380-530deg is used as feedstock. Feed enters the unit at the base of the riser
where it is vaporized and raised to the reactor temperature by the hot
catalyst. This mixture of oil vapor and catalyst travels up the riser into the
reactor. The gas oil commences to crack immediately when it contacts
the hot catalyst in the reaction zone. The now spent catalyst flows
from the reactor to the regenerator where the coke is burned off. The heat of
combustion raises the catalyst temperature to the 655-700deg range and
supplies heat, most of which is transferred to the charge in the riser.
In the fractionation section the reactor vapors are fractioned into recycle gas
oils, which are returned to the riser for further cracking and into the product
clarified slurry, heavy cycle oil (HCO), cracked cycle oil (LCO),
unstabilised gasoline and wet gas. The last two could be pumped and
compressed respectively to a gas concentration unit for further separation.

PROCESS EQUIPMENT:
Raw oil charge system: raw oil is used for preheating the fresh feed. Before
reaching the riser, the hot raw oil stream is joined by heavy recycle and
slurry from the slurry settler. During starting and shut down periods steam
can also be charged to the bottom of the riser, and it is also possible to
recycle unstabilised gasoline if necessary to control regenerator temperature
when burning off an excessive buildup of coke.
Riser: the reactor riser is a vertical pipe through which the mixture of
catalyst and oil vapors rise into the reactor. The diameter of the riser varies
across its length. The combined feed enters the riser through an injection
nozzle at the base of the riser. The resulting catalyst-oil vapor mixture is
raised to the designed reactor temperature by using the sensible heat of the
hot catalyst from the regenerator. If due to a major upset the supply of oil
should be reduced, the catalyst in the riser with slump and the riser will plug
with a mass of high-density catalyst. Immediate action will break such a
plug and the blasting steam connections on the riser are provided for this
purpose. It is also possible to inject steam to the base of the riser to prevent
the riser from plugging.
Most of the cracking reaction takes place in the riser, and a more desirable
product distribution is obtained by this riser cracking than by the cracking
obtained in the dense phase of the reactor.
Reactor: the catalyst enters from the riser into a cone on top of which is the
reactor grid. The cone and grid reduce the velocity of catalyst and oil vapors
rising from the riser so that stable dense bed of catalyst can be maintained
above the reactor grid. Because of the high velocity of the material leaving
the riser, a target is suspended below the grid directly opposite the riser to
prevent rapid erosion of the grid.
The oil vapors disengage from the catalyst in the reactor dense phase, and
leave the reactor through single stage cyclone separators suspended from the
reactor top head. These cyclone separators remove entrained catalyst and
return it to the dense phase of the reactor.
The main functions of the reactor are:
(a) to provide a zone for the final cracking of the oil vapors. When desired
the height of the dense bed above the reactor grid can be changed to vary
the contact time (space velocity) and thus have additional control over
the cracking severity.
(b) To provide a disengaging space for the separation of catalyst from oil
vapors.

(c) To provide a place for the cyclone separators, which recover most of the
entrained catalyst and return it to the catalyst bed.
Reactor standpipe: the catalyst leaves the reactor a standpipe on the bottom
of which is the catalyst slide valve. The head of catalyst standing in the
reactor standpipe produces enough pressure to overcome the differential
pressure between the reactor and regenerator, and causes flow through the
slide valve.
Regenerator: the regenerator has a lining of insulating refractory concrete
gunnited on a reinforcing support. This lining is necessary to protect the
metal wall of the vessel from the high temperature at which the regenerator
operates, and should keep the outer of the regenerator below 450deg F at all
times. The coke deposited on the catalyst in the reactor is burned off by air
distributed evently throughout the regenerator by the pipe grid at the bottom.
The flue gas rises from the dense bed of catalyst in the regenerator. Passes
through six two-stage cyclone separators and leaves from the top of the
vessel. As in the reactor, these cyclones return the entrained catalyst to the
dense catalyst bed. The flue gas leaving the top of the regenerator passes
through a double disc flue gas slide valve, which maintains the back pressure
on the regenerator. In normal operation, catalyst bearing about 1% coke
enters the fluidized bed, which is maintained at about 1150-1250degF by the
combustion of the coke. Sometimes, such as during start up, there is
insufficient coke to maintain the temperature of the regenerator bed in which
case torch oil can be injected through the two torch oil nozzles located above
the grid. It is also possible for excessively high temperatures to result from
an upset, such as a crash shut down, and water sprays are usually provided to
permit the injection of water just below the inlet of each set of cyclones.
Regenerator standpipe: the hot catalyst leaves the regenerator through an
alloy pipe at the bottom of which is the regenerated catalyst slide valve,
which is flanged into the Y at the base of the riser. The regenerated
catalyst slide valve is reset by a reactor temperature controller.
Air Heater: a direct-fired air heater is normally used to heat up the unit
during startup. It is located on the main blower discharge line upstream of
the regenerator grid. Normally, the heater is only fired during startup,
although on rare occasions at very charge rates, it may be used while the unit
is on stream. It is important that the air heater outlet temperatures be raised
and lowered at a maximum rate of 230degF per hour to reduce the stress,
which could be produced in the regenerator grid by rapid temperature
changes.
Torch Oil System: torch oil is used to heat up the catalyst inventory in the
regenerator on startup, and occasionally to extinguish after burning during

upsets. Raw oil from the discharge of the raw oil charge pump is injected on
hand control, through nozzles located above the grid. The oil is atomized
with steam. When torch oil is not being used, the atomizing steam pressure
should not exceed the regenerator pressure by more than 5 psi in order to
minimize breaking up of catalyst.
Instrumentation: fluidized catalyst behaves like a liquid so that the
pressure at any one point in the system can be measured with a pressure
instrument, and the difference in pressure between the top and bottom of the
vessel will give a measure of the catalyst inventory. However, if the catalyst
particles were to back into the instrument connections from the body of
fluidized catalyst, the connection would become plugged.

MEROX UNIT
INTRODUCTION: The purpose of this unit is to improve the quality of
petroleum product obtained from various units. Removing corrosive and
odourful compounds from product makes this improvement. This unit
provides pure products as per requirement for treatment of various products
of refinery which are as following;
(1) Kero/ATF Merox unit
(2) SR. LPG Merox unit
(3) VB Naphtha Merox unit
(4) CR. LPG Merox unit
(5) FCC Gasoline/SR Naphtha Merox unit

THEORY OF MEROX TREATMENT:

Straight (SR) petroleum products obtained from atmospheric distillation may
contain hydrogen sulphide and mercaptans. FCC Gasoline also contain
hydrogen sulphide and mercaptans to a greater degree compared to SR.
products.
H 2 S Can be easily removed by washing the petroleum product with
dilute caustic solution. And for reducing mercaptans level the merox
process is used in refinery.
Merox process can be divided in to following section ,
(a) Pretreatment, for removal of hydrogen sulphide and naphthenic acid,
if present.

(b) Extraction section, where required for removal of caustic soluble

mercaptans and thus reduce sulphur in the treatment products.
(c) Sweetening,for conversion of mercaptans to disulphide.
(d) Post treatment, to remove caustic haze and to control properties not
affected by merox product

BITUMEN BLOWING UNIT (BBU)

INTRODUCTION: bitumen blowing unit is designed for producing
0.5MMTPA bitumen by air blowing the vacuum residue above 530C air
blowing of vacuum residue considerably increases the contents of gums and
asphaltanes. Bitumen is colloidal solution of asphaltenes and associated high
molecular gums. Asphaltene contents influences it solidity and softening
point. Gums increase bitumen binding property and electricity.

PROCESS FLOW DESCRIPTION:

(A)FEED SUPPLY SYSTEM: the unit receives hot short residue and
cold feed from tanks as per requirement .the hot feed goes to reactors at
200-210C in two parallel streams. The cold feed from the tanks is carried
to unit by pumps and discharged through unit heater for heating to reaction
temperature.
(B)BITUMEN FURNANCE: it is natural draft furnace with
convection and radiation zone. The convection section forms rectangular
box while the radiation section is of cylindrical shape. The two sections are
having horizontal and vertical (hair pin type) feed coils respectively.
The furnace is provided with one oil-cum gas burner at its base.
The feed first picks up heat from the fuel gases in the convection section and
then it is heated in radiation zone coils.
The feed is heated up to 230C.The two passes join together at the outlet
of furnace and are routed to reactor in two parallel streams.
(C) REACTORS: Feed to reactor is controlled by feed control valves.
Compressed air at 80C is supplied through spargor provided at reactor
bottom .Air flow to reactor is controlled by two controls valves. Oxidation
of residue is carried out at a temp. of 240-260C. reactors middle zone
temp. is maintained by varying quench water through control valves
installed in the discharge line but the facility is kept isolated currently.

Finished bitumen is pumped out from the bottom while oxidation gases
passes through overhead line of reactor.

(D) FINISHED BITUMEN CIRCUIT: finished bitumen from

reactor at 240 260C is pumped in two groups of air coolers. Product is
cooled up to 170-200C By regulating air supply controlled by outlet lovers
as well as fan blade angle. Facilities exist for routing a portion of cooled
bitumen to reactors for deeper oxidation. Cooled bitumen is routed to
storage tank.
(E) REACTOR OVER HEAD SYSTEM: from the top of reactors,
the hydrocarbon vapors and unheated air about 220-240C go parallel to air
coolers vapors is condensed and cooled up to 170C. The combined vapor
liquid mixture from the coolers gas to oxidation gas separators which
operate in parallel.
(F) OXIDATION GAS SEPARATORS: the vapor liquid mixture
coming from air cooler is separated at around 170C is periodically pumped
by pumps through air cooler .oil is cooled up to 80C and sent to FPS
tanks/IFO tanks. The uncondensed gas at a temp. of 170C passes through
demisters in the overheat lines, liquid separated is trained to OMS in case of
high level in demesters. The two gas streams from the demisters joins a
common header and go to incinerator for final combustion.
(G) INCINERATOR: The gases enter in incinerator from the top where
it is burnt at a temp of 550C to 580C. Incinerator is a natural draft furnace
with cylinder top. The bottom portion forms a rectangular box. It has two
oil-cum gas burner to maintain box temperature. Combustion air for in
coming gases and burner fuel is supplied by blower. Fuel gas to incinerator
is supplied at a pressure of about 4.0kg/cm2.
(H) COMPRESSORS: compressors have been provided in the unit to
supply air for the oxidation reaction in reactor. The compressors are
horizontal reciprocating balanced, opposed piston double stage, double
acting water-cooled type. Compressed air is received in a air receiver and
then sent to reactors.
(I) FLUSHING OIL SYSTEM: Flushing oil is generally light oil in
the range of oil. This is used to displace heavy oil from the process
equipment lines etc. for flushing purpose unit receives FCC light cycle oil or
HGO/LGO from AVU through 80mm line.

OIL MOVEMENT & STORAGE I

(PRODUCT RECEIPT AND BLENDING SECTION)
This unit is used to:
a) Preparation and supply of feed to unit.
b) Blending of intermediate products.
c) Receipt, storage and dispatch of finished products.
d) Measurement of petroleum products Gauging, sampling etc.
e) Supply of internal fuel oil to Units TPS.

GENERAL DISCRIPTION OF TH E TANK FARM:

The tank farm in the receipt and blending section of OM&S consists of
different storage tanks for the different intermediate as well as finished
products. Some of the important points are:
(A) DIP OR PRODUCT IN A STORAGE TANK: It is the height of the
oil from the datum plate up to the top oil level.
(B) DATUM PLATE: Inside the tank there is a small horizontal plate
located approximately 5cms above the tank bottom surface. At the time
of taking the dip of oil leveling a tank the bob connected with the dip
tape first touches the above plate. This plate is called the datum plate.
(C) TANK PAD :It is the developed area with brickwork, concrete and
other bituminous material upon which the whole tank shell is resting.
(D) TANK DYKE: In is a bound made up of soil surrounding the tank. The
purpose of providing dyke is that oil will not spread out in the event to
any leakage from the tank shell.
(E) SAFE FILLING HEIGHT: It is the height up to which the tank can
be filled up safely.
(F) REFERENCE HEIGHT: It is the difference in height between the
datum plate and the sharp edge in the rectangular groove provided at
the top of the dip hatch pipe.
(G) DIP HATCH PIPE: It is the cylindrical pipe extending from the
bottom of the tank to the top with a cover at the top. Through this pipe
only, the dip tape with bob is allowed to enter inside the tank for the
purpose of taking dip.
(H) CRITICAL ZONE OF FLOATING ROOF TANK: Depending on
the height of the leg provided with the pontoon roof of floating roof of

the tank starts floating at a certain dip with increase in dip. Between
these two dips the pontoon remains slightly in tilting condition. When
the dip of any floatation roof tank falls between the above two dips, the
dip of the tank is said to be in critical zone.
(I) ROOF DRAIN: In floating roof tank, there is a pipe with swivel joint
from the center of the pontoon roof. The line extends inside the tank
and comes outside the shell from the lower portion of the tank.
Rainwater gets out through this drain line.
(J) SYPHON DRAIN: At the lower portion of the tank shell, one siphon
drain nozzle has been provided to get the water drained from the
bottom of the tank after being settled.
(K) EMERGENCY ROOF DRAIN: In a floating roof tank, If there is any
leakage in the roof drainpipe inside the tank, it cannot be operated .In
that case the roof drain on the top has to be blinded. An emergency
drain has been provided for draining water.

STORAGE TANKS:
There are three types of storage tanks,
(A) FIXED ROOF TANKS: Fixed roof tanks are used for storing low
volatile products. These are vertical cylindrical vessel. The fixed roof is
provided with internal truss support.
(B) FLOATING ROOF TANKS: Floating roof tanks are for storing
products having high vapor pressure. These tanks have an increased
operation at safety bought about by the absence of vapor space above
the liquid as the roof rests on the fluid.
(C) FLOATING CUM FIXED ROOF TANKS: These tanks have got the
advantages of both fixed and floating roof tanks and are particularly
suited to volatile products in which entry of rain water is not
permissible.

OPERATIONS AT BLENDING STATION:

Blending station operations are as following:
(1) VB BLENDING FACILITY: Light residue (LR) from atmospheric
distillation column and short residue(SR) from vacuum distillation
column are blended and stored in two tanks 707 and 708.

(2) VBN, FCC GASOLINE BLENDING FASCILITY: FCC Gasoline

of unit from VBU is blended through R/D line stored in tanks.
(3) FFS BLENDED FACILITY: For FFS the LR of AVU, SR of AVU,
VGO(s)/HVGO OF AVU, VBFO of VBU, LCO of FFCU are blended
and stored in FFS tanks.
(4) FO BLENDING FACILITY: LR, VBFO, LGO, LCO,
VGO(s)/HVGO and CLO are blended and stored in FO tanks.
(5) HSD BLENDING FACILITY: LGO, HGO, from AVU, SKO, LVGO
and LDO are blended for blending and stored in HSD tanks.
(6) LDO BLENDING FACILITY: For LDO Blending LGO, HGO, LCO,
SKO, LR, LVGO, LDO are blended and stored in LDO tanks.
(7) TEL BLENDING STATION: The pump station provides facilities for
blending the following things;
(a) TEL (Tetra ethyl lead)
(b) Dye
(c) Antioxidant.
TEL is a poisonous compound. It may be absorbed into the body
through the skin when exposed to it. Hence it must be handled carefully.
The addition of TEL is required to improve the octane number of
motor spirit .The Dye is added to meet the statutory regulation for
identification of the product.
The actual dosing rate of TEL depends upon the base octane, the
proportion of the intermediate product mix of the components such as FCC.
Gasoline line, HAN VB naphtha and is decided by R&D section.

OMS-II (OIL MOVEMENT & STORAGE II)

OM & S-II has the three section as following:

(1) Bitumen Drum filling section.
(2) L.P.G. section
(3) Effluent treatment plant (ETP)

1.BITUMEN DRUM FILLING SECTION

In this section pumps from the storage tanks to the supply line to heat
exchangers pump the bitumen. There are filling devices having the capacity
of filling 2000 drums a day. The hot molten bitumen at temp about 105
degrees centigrade is filled in drums .The capacity of each drum is 160kg of

Bitumen. The filling devices have many facilities like filling weight
indicator, valve, steam supply facility and hot water facility. This is an
automatic device. Loading the railway wagons dispatches these filled drums.
The drums are kept at yards for 48 hours for cooling the hot bitumen. On
other hand the tankers dispatched the bitumen by road.

2.LPG SECTION
STORAGE OF LPG: In this section the LPG is stored in spherical vessel
called HORTON SPHERE. There are six Horton spheres with a capacity of
1500M 3 each. Three spheres of them are for storing straight run LPG and
other three are for storing cracked LPG .one of Horton sphere has direct
connection to receive both SR and CR LPG. All spheres are made of
stainless steel are insulated with mineral wool of 50mm thickness. There are
several safety valves on the surface of sphere. The thermal valves will work
immediately if temperature goes above 80 degrees centigrade by thermal
relay fuses-spheres are provided with automatic level indication, mechanical
gauge as well as pneumatic level indication. For draining separated water
from spheres the drains are provided with two block valves and a remote
controlled valve. The protection system is provided against over pressure as
well as fire around the spheres. Methyl mercaptans are mixed in LPG for
safety to make it full of odour. LPG is dispatched by following two methods,
(1) By bottling LPG cylinders
(2) By bulk loading /unloading
(i) Bulk dispatch by road
(ii) Bulk dispatch by train

LPG BOTTLING PLANT: LPG filling plant is designed to fill

100000MT per annum of LPG in domestic cylinders .The empty cylinder
received from trucks and wagons are stored in storage sheed .The
cylinders are counted manually and visually inspected .The defective and
five year old cylinders are marked and separated .The cylinders are
loaded vertically on the chain conveyor for transportation to the filling
machines .The cylinders from slat roller conveyor of the filling machine
from where they are loaded on filling machine turn automatically as per
requirement of filling UN5 carousel machine each having 12 filling
points .With a capacity of filling 720 cylinders per hour .The filling head
is connecter to cylinder valve ,and cylinder is opened when 14.2kg of
LPG is filled in cylinder .After the automatic discharge the filled

cylinders pass over chain conveyor .Check weight is done for detection
of over filled and under filled .Checked cylinder are tested in water for
checking leakage in cylinder .Full checked cylinder are sealed and
dispatched through loaded trucks.

(I) BULK LOADING : This facility is provided for dispatching

97000MT per annum of LPG by road and rail transfer.

(II) BULK LOADING BY ROAD : There are four filling point, each
having a weight bridge of 30MT capacity with dial type seal flexible
basis are connected with filling and the vapor return lines .A flow meter
is provided on the main filling head.

3.EFFLUENT TREATMENT PLANT

INTRODUCTION:
The main objectives of plants in Mathura refinery are:
(a) The recovery of oil from oily water.
(b) Removal /Recovery of suspended solids.
(c) Reduction of biological oxygen demand (BOD) .

SOURCES:
The following liquid streams are collected and segregated into 3 basic
streams based upon the nature of waste water and treatment needed to be
given so as to remove the pollutants and contaminates from the waste
water.

(a) INDUSTRIAL SEWER (IS): In this sewer process oily water

(b)
(c)
(d)

from units, equipment, sample points, pump house drains, electric

desalter drains, loading gantries, tank drains etc . comes .
SALTY WASTE WATER SEWER (CS):In this sewer
water from crude tank drains and crude booster pump house drain
comes.
STORM WATER SEWER (SS):In this sewer rain water
from tank farm dyked areas comes.
DOMESTIC SEWAGE (DS):In this sanitary sewage from
toilets and lavatories provided in the refinery comes.

(e) FRESH WATER SEWER (FS):In this water used for other
(f)

activities not fully oily comes.

Caustic bearing waste water from MEROX, VBU and FCC units
comes.

TYPES OF TREATMENT
Waste water treatment includes three steps,
(i)
Physical treatment
(ii) Biological treatment
(iii) Chemical treatment

(I) PHYSICAL TREATMENT

In this treatment the physical process separates suspended solids and free oil.
Oily water from different sources is coming to effluent sump by gravity,
where from it is pumped to API oil separators. If the in flow is more than
450M 3 /hr. Excess in flow will be stored in Guard basins .In separators the
velocity of the water is slowed down considerable. At such low velocity
solid settle at the bottom and free oil floats on the water surface. The
skimmer which are slowed and provided with manual gear operation
mechanism, are provided for skimming the oily layer .A scrapper
mechanism consisting of wooden lags provided on two endless chain
running parallel is provided for skimming of oil while moving At the top of
liquid level and scrapping the oily sludge. HOPPER for collection of sludge
is provided. The slop oil collected in with drain through pipe skimmers and
load to slop tanks in ETP. Waste water from API out let goes to equalization
basin. After drain of water from tank and heating to 70 degree centigrade,
slop oil will be pumped to tanks in IFO, where from it will be processed in
units with crude.
Oil skimming facility is provided here to single high rate trickling filter, oily
sludge from oil separators will be pumped to oily lagoons. After removing
supernatant, sludge will be removed manually and disposed off.

BIOLOGICAL TREATMENT : This treatment is occurred first in

trickling filter. It removes about 70% of the total organic load viz BOD
phenols and practically all sulphides. It consists crushed rock to facilitate
anchorage and space for biological activity as well as to per unit circulation
of air. The filter is circular in shape and it enters at the discharge pipe with

eight distributor arms, which sprinkles water all over the surface and entire
waste water is collected by gravity in sump from the bottom. Where
remaining soluble BOD is removed completely (30% BOD). Suspended
solid is given sufficient resident time in aerators to completely stabilize the
waste water and the mixed liquor is sent to final clarifier and a portion of bio
sludge is recycled. The waste water and mixed liquor is separated in final
clarifier.the treated water firm final clarifier goes to gard ponds.

CHEMICAL TREATMENT: caustic bearing wastes are collected in

two storage tanks. Spent caustic from the tanks, falls in sump, where from it
is pumped to caustic API oil separator. Here it is diluted with water at the
inlet channel to 150M 3 /hr.
From API oil separators water goes to pH adjustment chamber where the pH
is adjusted to 6.5-7.5 by dilute H 2 SO4 then to reaction tanks.
Cl2 + Na 2 S 2 NaCl + S

FeSO + Na S
4

Na SO
2

FeS

The floes formed here goes here to flocculation chamber where:

(a) Additional time is provided to complete the reaction.
(b) To promote the floe growth.
Then the floe formed out of chemical reaction is settled at clarifier cum
thickener (CCT), where from the clear water goes to equalization basin inlet.

AMINE REGENERATION UNIT (ARU)

PROCESS FLOW DESCRIPTION:
This section covers the process flow description of amine absorption unit
and amine regeneration unit.
ABSORPTION: the feed of AAU (Amine absorption unit) is the gas
from stabilizer over head of VBU. Gas contain 40.17kg mole/hr of H2S and
coming out of sour gas knock out drum in FCC unit and sour gas coming
3.46kg mole/hr of carbon dioxide. It enters the absorption unit at 5.5 kg/cm2
pressure and temp of 43 8C.
Regenerated di ethanol amine (DEA) solution (15-25% weight) coming from
amine regeneration section at a press. of 8.1 kg/cm2 and a temp.of 458C
enter the amine absorber at controlled flow. Amine absorber is a vertical

column of 20 trays of single pass valve type. The reaction are involved in
absorber are;
R2 NH + H 2 S R2 NH 3 S

R NH + CO + H S
2

( R2

NH ) CO
3

where R is CH3CH2OH group and reaction are exothermic.

Rich DEA containing absorbed H2O and CO2 leaves absorber from bottom
to the amine regeneration unit. At top of absorber a demister is provided to
prevent any carry over of amine along with the gases. Anti foaming agent
dosing is absorber is started to prevent foaming of amine solution. Vent
valve and safety valve are provided in column. The sweet fuel gas stripped
off its H2S and C2O leaves the absorber from top and enters the knock out
drum and after knocking gases enters the fuel gas system.
AMINE REGENERATION UNIT: In the amine regenerator the rich
DEA stripped of its absorbed sour gases H2S and CO2 using steam as
stripping medium .So the regenerated amine can be reused in the absorbers.
The amine regenerator is a tall vertical column 19670 mm height and has
O.D. of 1800mm at top and 2000mm at bottom .It contain 23tray in which
1to 20 tray are valve type and 21 to 23 are of baffle type .The feed enters at
the 20th tray amine reboiler heated by LP steam and gases for stripping. LP
steam is also provided for stripping and it enters the column from bottom
below Ist tray, the steam strips out the absorbed H2S and CO2 present in the
DEA solution .The chemical reaction involved are;
RNH 3 S R2 NH + H 2 S
( R2 NH 3 ) CO3 R2 NH + CO 2 + H 2 O

The liberated sour gas and steam at 112.3 8C and 0.8kg/Cm2 press. Leave
the regenerator from the top and enters the regenerator over head condenser.
Where the gases are cooled and steam is controlled to 45 8C deg by cooling
water on tube side .The condensate and the gases flow freely from the
condenser to the reflux drum .The sour gases from the reflux top go to the
sulphur recovery unit for production of sulphur. From the bottom of the
reflux drum refluz is pumped to the regenerator top above 23rd tray at 5.2
kg/cm2 press. Level is controlled in reflux drum by level controller. From
below 18th tray of regenerator lean amine flows into the amine reboiler
where it is heated by LP steam on the tube side. The reboiler has got two
compartment separated by gravity. Anti foaming agent dosing, needed in
regenerator, is done at amine absorption unit at FCC section. From the
regenerator bottom lean absorption unit at FCC section. From the

regeneration bottom lean amines at 120 8C and 1.05kg/cm2 press. Enters the
DEA feed bottom exchanger. Where it gets cooled from 120 8C to 76.3 8C
by exchanging its heat with the incoming rich DEA solution. From
exchanger lean amine is pumped out to lean amine cooler where cooling
water cools amine from 76.3 8C to 45 8C. From cooler a part of lean amine
is sent to the top of the amine flash column and other to filters

SULPHUR RECOVERY UNIT (SR)

INTRODUCTION: Sulphur recovery unit consists of two identical unit
A&B. The process design is in accordance with common practice to recover
elemental sulphur, known as the clause process. Each unit consist of a
thermal stage in which H S is partially burnt with air followed by two
catalytic stages. A catalytic in cinerator of tail gas has been incorporated in
order to prevent pollution of the atmosphere.

SULPHUR RECOVERY PROCESS: The sulphur recovery process

is applied in the present design which is known as the CLAUSE PROCESS
is based upon the combustion of hydrogen sulphide with a ratio controlled
flow of air which is maintained automatically in sufficient quantity to evolve
the complete oxidation of all hydrocarbons and ammonia present in the sour
gas feed and to burn 1/3rd of the H2S to SO2 and water;

H S + 3 / 2O
2

SO2 + H 2 O + HEAT

The major percentage of the residual H 2S combines with the SO2 to forms
according to the equilibrium reaction;

SO

+ 2H 2

3S + 2 H 2

Sulphur is formed in vapor phase in the main combustion chamber. The

primary function of the waste heat boiler is to remove the major portion of
the heat evolved in the combustion chamber. The secondary function of
waste heat boiler is to condense the sulphur, which is drained to a sulphur
pit. At this stage 60% of the sulphur present in the sour gas feed is removed.
The third function of the waste heat boiler is to utilize the heat liberated
there to produce the low pressure steam (4.00 Kg/cm2).

The process gas leaving the waste heat boiler still contains a considerable
part of H2S and SO2. Therefore the essential function of the following
equipment into shifts the equilibrium by adapting a low reaction
temperature. Thus removing the Sulphur as soon as it is formed.
Conversion of sulphur is reached by a catalytic process in few subsequent
reactors containing a special Synthetic alumina catalyst.
Before entering the first reactor the process gas flow is heated to an optimum
temperature by means of a line burner with mixing chamber in order to
achieve a high conversion.
In the line burner mixing chamber the process gas is mixed with hot flue gas
obtained by burning fuel gas with air. In the first reactor, the reaction
between the H2S and SO 2 recommences until equilibrium is reached. The
effluent gas from the first reactor passes to the sulphur condenser where at
this stage approx. 29% of the sulphur present in the sour gas feed is
condensed and drained to the sulphur pit. The total sulphur present in the
sour gas feed. In order to achieve a figure of 94% sulphur recovery the sour
gas is subjected to one more stage. The process gas flow is once again
subjected to preheating by means of a second line burner then passed to a
second reactor and the sulphur condenced in the second condenser
accomplishes a total sulphur recovery 94%.
A sulphur coalescar is installed downstream of the last sulphur condenser to
separate entrained sulphur mist.
The heat released by the subsequent cooling of gas and condensation of
sulphur in waste heat boiler and condenser results in the production of lowpressure steam. The tail gas from sulphur coalescer is sent to a catalytic
incinerator to convert the residual H2S and sulphur vapor to SO