VOCATIONAL TRAINING REPORT AT INDIAN OIL CORPORATION LTD GUJARAT REFINERY

(JUNE-JULY 2012)

PREPARED BY:

ASHISH RAJESHBHAI KAVAIYA

Roll Number :- U10CH010 (B-TECH-II IN CHEMICAL ENGINEERING) SARDAR VALLABHBHAI NATIONAL INSTITUTE OF TECHNOLOGY, SURAT

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PREFACE
India has definitely become a strong country as far as the petrochemical industry is concerned. India has undoubtedly strengthened its position in the international market by roping in foreign investment and trying to establish its strong abroad. In the present area, it has become necessary to compete on the global stage. It is equally important to have practical as well as theoretical knowledge. Theoretical knowledge can be easily acquired from books and publications, but one has to pass through an on-site training phase for practical knowledge. Having said this, one has to observe and study the equipments used for the process, its construction, start up and shut down procedures, operating problems, its solution, emergencies, etc. The theories and usual practices cited in books and literature differ up to an appreciable extent from the industrial practices. Another attractive feature is to learn industrial management and discipline, which is equally important in life. This is only possible in an industrial training. In short, the in-plant training makes a better engineer and a better manager who can serve the industry with best of his ability.

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ACKNOWLEDGEMENT
The summer training at Indian Oil Corporation Ltd., Gujarat Refinery was a wonderful experience. Whatever I learnt during the training has been brought out in the form of this training report. I, hereby take the opportunity to thank all the people who have imparted their invaluable knowledge to me. I bestow my gratitude to Mr. PK Sahai,Dy Manager (Trg. & Dev.), Mr.C.P.AMBEDKAR, Sr. Officer(Trg. & Dev.) and Mr. N.H.PATEL for granting me the permission to obtain training at Indian Oil Corporation Ltd, Gujarat Refinery. I am thankful to Mr.P.V.Solanki, Chief Production Manager (CPNM),Gujarat Refinery, my industry mentor, for continuously guiding and encouraging me at each step of my training. He not only solved my difficulties, but also shared his immense experience of his service in the industry. This was the most valuable thing I earned at Indian Oil Corporation Ltd., Gujarat Refinery. My training would have been remained incomplete without my mentor. I wish to warmly thank Mr.AB Damor Production Manager(GHC),Mr.K M Taboli Production Manger(GR-1),Mr. A K Roy Production Manger( LAB/MSQU) and Mr. S.BOSE, Production Manager (GRE) for their consistent guidance and support in their respective units throughout my training and for constantly ensuring that the training is opening up new aspects of chemical industry for my learning. I am highly indebted to Dr. Z.V.P MURTHY (Head of Department, Chemical Engineering, SVNIT) for deputing me to Indian Oil Corporation Ltd. for training. I, finally, would like to thank all the staff and officials of Indian oil Corporation Ltd., Gujarat Refinery for all the help they provided during the training.

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CONTENTS
1. Indian Oil Corporation Ltd. (IOCL) Overview ............5 Company Profile ..5 Refineries .............6 Corporate Mission ...........6 Business Activities/Objectives ............7 2. Vision .8 3. Expertise available with Indian Oil ..............10 4. Gujarat Refinery ....13 Introduction .............13 History .............14 Technology Leader ..15 Crude Processing .............15 Product and End Uses ..15 5. Important Units of Gujarat Refinery ............17 6. Gujarat Refinery Expansion Unit (GRE) ..18 Crude Distillation Unit (CDU) ..................19 Vacuum Distillation Unit (VDU) ..................26 Vis-breaker Unit (VBU) .....33 Bitumen Blowing Unit (BBU) ...................39 7. Gujarat Refinery Secomdary Processing Facilities....45 Feed preparation Unit .46 Fluidized Catalytic Cracking...47 8. Gujarat Hydro Cracker Unit ...54 Hydrogen Unit..55 Hydro Cracker Unit..60 9. Motor Spirit Quality Upgradation Unit........69 10. Catalytic Reforming Unit.82 11. General Safety Regulations .89

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INDIAN OIL CORPORATION LTD

Company Profile
Indian Oil Corporation Ltd., is an Indian public-sector oil and gas company. It began its operation in 1959 as Indian Oil Company Ltd. The Indian Oil Corporation Ltd was formed in 1964, with the merger of Indian Refineries Ltd. (established in 1958). It is Indias largest commercial enterprise, with a sales turnover of Rs.2,85,337 crore, the highest ever for an Indian company, for the year 2008-09. Indian Oil is also the highest ranked Indian company in the prestigious Fortune Global 500 listing, having ranked 105th in 2009. It is also the 18th largest petroleum company in the world. Indian Oil and its subsidiary account for approximately 48% petroleum products market share, 34% national refining capacity and 71% downstream sector pipelines capacity in India. The Indian Oil Group of companies owns and operates 10 of Indias 20 refineries with a combined refining capacity of 60.2 million metric tones per annum. These include two refineries of subsidiary Chennai Petroleum Corporation Ltd. (CPCL). The Corporations cross-country network of crude oil and product pipelines, spanning more than 10,000 kms and the largest in the country, meets the vital energy needs of the consumers in an efficient, economical and environment-friendly manner. As the flagship national oil company in the downstream sector, Indian Oil reaches precious petroleum products to millions of people every day through a countrywide network of about 35,000 sales points. Indian Oil operates the largest and the widest network of petrol and diesel stations in the country, numbering over 18,278. It reaches Indane cooking gas to the doorsteps of over 53 million households in

nearly 2,700 markets through a network of about 5,000 Indane distributors. Indian Oils ISO-9002 certified Aviation Service commands over 63% market share in aviation fuel business, meeting the fuel needs of domestic and international flag carriers, private airlines and the Indian Defense Services. The Corporation also enjoys a dominant share of the bulk consumer business, including that of railways, state transport undertakings, and industrial, agricultural and marine sectors.

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Refineries :
Digboi Refinery, in Assam is Indias oldest refinery and was commissioned in 1901. Originally a part of Assam Oil Company, it became a part of Indian Oil in 1981. Its original refining capacity had been 0.5 MMTPA (million metric tones per annum) since 1901. Modernization project of this refinery has been completed and the refinery now has an increased capacity of 0.65 MMTPA. Guwahati Refinery, the first public sector refinery of the country, was built with Romanian collaboration and was inaugurated by Late Pt. Jawaharlal Nehru, the first Prime Minister of India, on 1st January 1962. Barauni Refinery, in Bihar, was built in collaboration with Russia and Romania. It was commissioned in 1964 with a capacity of 1.0 MMTPA. Its capacity today is 6.0 MMTPA. Gujarat Refinery, at Koyali in Vadodara, Gujarat, is Indian Oils largest refinery. The refinery was commissioned in 1965. It also houses the first hydrocracking unit of the country. Its present capacity is 13.70 MMTPA. Haldia Refinery is the only coastal refinery of the Corporation, situated 136 kms downstream of Kolkata in the East Midnapore district. It was commissioned in 1975 with a capacity of 2.5 MMTPA, which has since been increased to 5.8 MMTPA. Mathura Refinery was commissioned in 1982 as the sixth refinery in the fold of Indian Oil and with an original capacity of 6.0 MMTPA. Located strategically between the historic cities of Delhi and Agra, the capacity of Mathura refinery was increased to 7.5 MMTPA. Panipat Refinery is the seventh refinery of Indian Oil. The original refinery with 6.0 MMTPA capacity was built and commissioned in 1998. Panipat Refinery has doubled its refining capacity from 6.0 MMTPA to 12 MMTPA with the commissioning of its Expansion Project.

Subsidiary refineries are Bongaigaon Refinery (2.95 MMTPA) and Chennai Petroleum (9.5 MMTPA).

Corporate Mission
To achieve international standards of excellence in petroleum refining, marketing and transportation with concern for customer satisfaction. To create a modern technology base for self-reliance, growth and development of the business. To contribute to the national economy by providing adequate return on investment and by setting high standards of leadership in productivity and total quality. To help to enrich the quality of life of the community and preserve ecological balance and national heritage.

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Business Activities/Objectives 1) Refineries and Pipelines Division

Operate and maintain the existing refineries and pipelines Improve operating factor Maximize capacity utilization Optimize energy use Protect environment Modernize and increase capacities of existing refineries/pipelines by low cost debottlenecking/addition of new facilities Install new crude oil/product pipelines Diversity into petrochemicals Professional growth and self development of employees

2) Marketing Division
To ensure and maintain continuous and uninterrupted supply of petroleum products all over the country To achieve excellence in consumer satisfaction Advice Govt. on perspective plans and policies for the industry Professional growth and self development of the employees Market leadership in the industry

3) Research and Development

Develop formulation for lubes and greases. Nearly 600 lubricants formulation developed of international quality Develop and improve refining processing technologies Expertise on waxy fluids transportation by pipelines Fuel products quality improvement Evaluate catalyst additives Assess remaining life of equipments Develop synthetic lubricants and greases Developing biodegradable as well as environment friendly lubricants Developed kinetic model for Hydrocracker for prediction of product qualities at different levels Developed specific railway signal lamp operable with 18 mm smoke point kerosene Developed energy efficient household appliances like LPG burners, kerosene lamps for rural areas

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Vision Values
Indian Oil nurtures the core values of Care, Initiative, Passion and Trust across the organization in order to deliver value to its stakeholders. Care Stands for Concern Empathy Understanding Co-operation Empowerment Innovation Stands for Creativity Ability to learn Flexibility Change Passion Stands for Commitment Dedication Pride Inspiration Ownership Zeal & Zest Trust Stands for Delivered promises Reliability Dependability Integrity Truthfulness Transparency
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EXPERTISE AVAILABLE WITH INDIAN OIL

Debottlenecking
The crude oil refining capacity has been increased from 18.75 MMTPA to 24.55 MMTPA i.e 33% increase achieved mainly through in-house expertise. As such debottlenecking included necessary revamping of downstream Secondary Processing units as Offsite storage and dispatch facilities. All capacity increase projects were also associated with energy conservation and product mix improvement. Project management including procurement, construction, supervision, start-up and commissioning was undertaken by in-house expertise.

Technology Upgradation
Following technological developments have undergone in various refinery units: 1) FCCU Change of catalyst from amorphous to zeolite 2) CRU Change from monometallic to bimetallic catalyst Adoption of continuous catalyst regeneration technology 3) VBU Soaker Drum Technology 4) RESIDUE UPGRADE SOLVENTS Through hydrocracker from TEG to TTEG and from Phenol to Furfural NMP* (* Normal Methyl Pyridine)

Safety Management
Our refineries have a dedicated Safety Management team and also there is a Safety Management set-up at HO level. This team has engaged in the following activities: Constant upgradation/improvement in fire fighting facilities Regular HAZOP and HAZAN studies Risk analysis Disaster Management Plan/Mock Drill Safety Audit Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 10

Energy Conservation
All Indian Oil Refineries have Technical Audit section equipped with experienced engineers. Energy Conservation activities are undertaken in the following areas: Steam/power balance Heat Integration Co-generation based gas turbines Continuous Energy Audit Retrofitting Air Preheaters in old furnaces Replacement of inefficient equipments not amenable to modifications Optimizes heat recovery using pinch technology

Waste heat recovery

Environment Management
Refineries of Indian Oil maintain a constant vigil and follow-up on the various aspects of Environment Management. Elaborate treatment facilities have been provided in all refineries to handle the following effluents: Oil contaminated waste water Acidic/Alkaline waste water Fecal waste Sulphur Dioxide emission

The refineries effluents, both liquid and gaseous, are of superior quality and meet all stipulations laid down by the Government and the Pollution Control Boards. Environment Management activities in all IOCL refineries include: Modern Effluent Treatment Plants meeting stringent specification Reuse of treated effluent Sulphur Recovery Units Stack/ambient air monitoring and control Oily sludge minimization/treatment Environment impact studies/Environment Audit Establishing Occupational Health Centers

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Maintenance and Inspection

Indian Oil has 30 years of experience in Maintenance and Inspection of its refinery process units, offsite facilities, loading facilities and cross country pipelines. The Maintenance Departments of all the IOCL unit are responsible for carrying out the following: Shutdown Planning, scheduling and arranging of all resources for timely completion of the turnaround work PM Scheduling, implementation and monitoring Vibration monitoring, analysis and corrective action Failure analysis of static and rotary equipments and taking corrective actions Zero based budgeting Long term planning Technical Documentation Standardization of equipments and spares

Each refinery is having a separate Inspection Department which ensures reliability and safety of all static equipments. Primary functions of this department are: Quality Assurance Corrosion Monitoring Residual Life Assessment Non-Destructive Testing

Both Maintenance and Inspection Department are deeply involved in any process plant or offsite revamp job and give full assistance to the Project Department in timely completion of the project as well as their smooth commissioning.

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GUJARAT REFINERY
Introduction
Gujarat Refinery is the Indian Oils largest refinery, with a crude processing capacity of 13.7 million tones per annum. Indian Oils foray into the petrochemical sector also started at Gujarat Refinery with the successful commissioning of worlds largest single train Linear Alkyl Benzene Plant in August 2004. The refinerys success is built upon business and community partnerships with the people of Vadodara, as well as production of quality products that are compatible with the community and the environment. At the heart of the Gujarat Refinerys success, are its employees and their commitment to Indian Oils vision and mission. Gujarat Refinery is situated at Jawaharnagar near Bajwa Railway station on the broad gauge line between Mumbai-Ahmedabad on Western Railway at a distance of nearly 10 kms north of Vadodara. The refinery is spread over an area of 1424 acres out of which refinery units and offices cover about 859 acres. About 138 acres is developed as green belt area, which is home to all botanical species indigeneous to this region.

Its facilitates includes five Atmospheric Crude Distillation Units (ADU). The major secondary units include Catalytic Reforming Unit (CRU), Fluidized Catalytic Cracking Unit (FCCU), Diesel Hydro Desulphurization Unit (DHDS) and the first Hydrocracking Unit of the country. Through a product pipeline to Ahmedabad and a recently commissioned product pipeline connecting to BKPL product pipeline and also by rail wagons/trucks, the refinery primarily serves the demand for petroleum products in western and northern India.

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History
Following the conclusion of an Indo-Soviet agreement in 1961 February, a site for the establishment of a 2.0 MMTPA Oil Refinery in Gujarat at Koyali near Vadodara was selected on the 17th April 1961. The Soviet and Indian engineers signed a contract in October 1961 for the preparation of the project report jointly. The first Prime Minister of India, Pandit Jawaharlal Nehru laid the foundation stone of this refinery on 10th May 1963. The refinery was commissioned with Soviet assistance at the cost of Rs.26.00 crores and went on stream in October 1965. The first million tone Crude Distillation Unit was commissioned for trial production on 11th October 1965 and full production at the rated capacity was achieved on 6th December 1965. The throughout was further increased by 20% beyond the designed capacity in January 1966. Dr. S. Radhakrishnan, the then President of India, dedicated the refinery to the nation with the commissioning of the second Crude Distillation Unit and Catalytic Reforming Unit on 18th October 1966. The third 1.0 MMTPA crude distillation unit (AU-3) was commissioned in September 1967 to process Ankleshwar and North Gujarat crudes. In December 1968, UDEX plant was commissioned

for the production of Benzene and Toluene using feedstock available from CRU. By 1974-75 with in-house modifications, the capacity of the refinery was further increased by 40% to a level of 4.2 MMTPA. To process Imported crude the refinery was expanded during 1978-79 by adding another 3.0 MMTPA Crude Distillation Unit (AU-4) along with downstream processing units like Vacuum Distillation Unit (VDU), Vis-breaker Unit (VBU) and Bitumen Blowing Unit (BBU). By 1980-81 this unit started processing Bombay High crude in addition to the Imported crudes.

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Technology Leader
It is first amongst Indian Refineries in the following: First Riser Cracker FCCU in the country First Hydrocracker in the country First Diesel Hydro Desulphurization Unit First Spent Caustic Treatment Plant in Indian Refineries First Automated Rail Loading Gantry First LPG Moulded Bullets in Indian Refineries Operates Southeast Asias biggest Centralized Effluent Treatment Plant

Crude Processing
Gujarat Refinery is designed to process indigenous as well as imported crude oil. On an average it processes approximately 41500 metric tones of crude oil per day. Out of the crude slot it receives, the refinery processes around 50% imported crude. Gujarat Refinery achieved highest ever crude throughput of 13.85 MMTPA in the year 2008-09. The break-up of the various types of crude oil processed at Gujarat Refinery is as follows: South Gujarat Crude: 2.15 MMTPA; supply from ONGC South Gujarat crude pipeline. North Gujarat Crude: 3.70 MMTPA; supply from ONGC North Gujarat crude pipeline. Bombay High Crude: 1.16 MMTPA; supply from Salaya-Viramgam-Koyali pipeline. Imported Low/High Sulphur Crude: 6.84 MMTPA; supply from Salaya-Viramgam-Koyali pipeline.

Product and End Uses

Fuel Gas LPG Naphtha Motor Spirit Aviation Turbine Fuel(ATF) Superior Kerosene High Speed Diesel(HSD) Light Diesel Oil(LDO) Fuel Oil Bitumen Benzene Toluene n-Heptane ARO Linear Alkyl Benzene (LAB) Butene Fuel for Industrial Furnaces Cooking Gas Raw material for Petrochemicals Petrol for vehicles Fuel for jet aircrafts Illuminant domestic product Diesel for trucks, buses ships, etc. Small engines attached to irrigation pumps Industrial furnaces/boilers Road surfacing Raw material for Petrochemicals Raw material for Petrochemicals Used as solvent Used in aluminium rolling industries Detergent manufacturers Copolymer for producing polyethylene and polypropylene Methyl Tertiary Butyl Ether Blending in gasoline for increasing octane number and (MTBE) oxygen content Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 15

Food Grade Hexane(FGH)

Sulphur

Solvent for oil seed extraction. Glues/Adhesives for footwear. Polymerization reaction in pharmaceuticals and printing ink. Sulphuric acid and tyre manufacture

industries

like

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IMPORTANT UNITS OF GUJARAT REFINERY

1) Gujarat Refinery Unit-1 (GR-1) Atmospheric Distillation Unit-1 (AU-1) Atmospheric Distillation Unit-2 (AU-2) Atmospheric Distillation Unit-5 (AU-5) Catalytic Reforming Unit (CRU) 2) Gujarat Refinery Unit-2 (GR-2) Atmospheric Distillation Unit-3 (AU-3) Universal Product Dow Chemical Extraction (UDEX) Food Grade Hexane (FGH) Methyl Tertiary Butyl Ether (MTBE) Butene-1 Pilot Distillation Fraction (PDF) 3) Gujarat Refinery Expansion Unit (GRE) Atmospheric Distillation Unit-4 (AU-4) Vacuum Distillation Unit (VDU) Vis-breaker Unit (VBU) Bitumen Blowing Unit (BBU) 4) Gujarat Refinery Secondary Process Functioning (GRSPF) Feed Preparation Unit-1 (FPU-1) Fluidized Catalytic Cracker Unit (FCCU) 5) Gujarat Hydrocracker Unit (GHC) Feed Preparation Unit-2 (FPU-2) Hydrogen Generation Unit-1 (HGU-1) Hydrocracking Unit (HCU) Hydrogen Generation Unit-2 (HGU-2) Diesel Hydro De-sulphurisation Unit (DHDS) Sulphur Recovery Unit (SRU) Nitrogen Unit 6) Power Generation Effluent Treatment Cogeneration Plant (CGP) Thermal Power Station (TPS) Combined Effluent Treatment Plant (CETP) 7) South block 8) North block

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GUJARAT REFINERY EXPANSION (GRE)

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CRUDE DISTILLATION UNIT

(CDU)

INTRODUCTION
The atmospheric crude distillation unit under Gujarat Refinery Expansion Project is originally designed to process 3.0 MMTPA of 50-50 mixture of North Rumaila and Light Arabian crude oils. Subsequently in August 1986 unit was debottlenecked to process 3.3 MMTPA of crude. The unit has processed a variety of imported crude besides indigenously available Bombay High Crude. In December 1993, a major revamping of unit was done particularly for increasing the processing capacity of lighter crude i.e South Gujarat and Bombay High at the rate of 10,000 MT/day and also imported crude at the rate of 12,000 MT/day. In the revamp, a Pre-fractionator column was installed and total debottlenecking of crude Preheat Exchanger train done for improving crude preheat. In November 1999, the unit capacity was enhanced to 5.0 MMTPA by installation of additional heat exchangers and higher capacity pumps. An additional fired heater was also installed in parallel operation with existing furnace. FEED AND PRODUCT SPECIFICATIONS Feed Feed is 50:50 wt% of North Rumaila and Light Arabian Crude oils. Unit can process Bombay High Crude. Sr. No. 1 2 3 4 5 6 7 Sr. No. 1 2 3 4 Specification Density Molecular weight Avg. Boiling Point Viscosity at 40 C (cst) Water content vol% Sulphur content wt% Salt content wt ppm Product Specification Density Pour point Viscosity at 37. C (cst) Sulphur wt% Naphtha 0.6890 0.4 0.0137 Kerosene 0.7921 1.55 0.168 LGO 0.8390 3.92 1.07 HGO 0.862 8.02 1.85 RCO 0.9580 15 150-170 3.26 Imported Crude 0.8741 215 282 11.07 Nil 2.8 2.0 Bombay High 0.8172 3.47 0.1 0.22 537

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PROCESS DESCRIPTION The total process can be divided into following sections: Crude Feed to Unit The different types of crude i.e Imported, Bombay High and South Gujarat are sorted in different tanks. Before feeding to the unit, water in the crude is separated by settling (minimum 24 hours) and then drained to OWS. Booster pumps located in offsite area will take suction from the tanks and delivers into the pump suction. Normally two of the three pumps are running. For processing slop, slop pumps are used to inject a measured quantity into the discharge of booster pumps. In crude pump suction, demulsifiers (3 to 4 ppm), caustic solution (about 2% strength) and wash water (2 to 3% on crude flow) are injected for effective desalter operation. Crude Preheat-1 There are total 15 nos. of heat exchangers in this section where crude is preheated to 1351 0 C before going to desalter. Crude, which is at ambient temperature, goes to the heat exchanger where it is treated against LGO and heated upto 0 C. Crude is further divided into two parallel passes with the help of a differential temperature controller DTC (3 way C/V). Both the passes travel through separate heat exchangers, exchange heat with products and are heated upto 1 0 C. Crude from the passes combine together and goes to desalter. Desalter The function of desalter is to remove salt and water, which always remains in the crude. The removal of salt and water is very important as acid vapour is generated from these salts at higher temperature at fractionator top portion. Salt also creates fouling problem in the exchanger at higher temperature. The desalting process consists of three main stages-heating, mixing and separation. For effective separation of salt and water from crude oil, it is heated upto about 1 0 C thoroughly mixed with extra water (3-4% on crude flow) by passing through mixing valve at the inlet of desalter (mixing valve pressure drop is generally kept at about 1.0 kg/sq.cm). The extra water is added to collect and dissolve all the water soluble salts in the crude. The rate at which water is injected into the crude is dependant primarily upon the salt and BS&W content of crude being treated. In some instances, it is not possible to achieve sufficient mixing across the mixing valve alone provision is therefore given to inject water ahead of desalter heat exchangers. This water is preheated to 100 C. The mixing valve, with isolation and bypass facility, is located at the inlet of the desalter. By varying pressure drop across the valve the desired mixing can be achieved. The normal operating pressure is 10.5 to 11.0 kg/sq.cm(g). Crude Preheat-2 Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 21

 Booster pump pumps crude from desalter outlet to one of the heat exchangers where crude is treated against Kero CR. At outlet, the crude flow is divided into two parallel passes by DTC. Crude in both the passes exchanges heat with LGO and RCO respectively. Both the passes combine in the end where the crude temperature is around 175 C. The two passes that combine are again divided into two passes, and is treated against HGO CR. LGO CR and HGO. Crude after passing through a series of heat exchangers is fed to the flash zone of prefractionator column at a temperature of 225 C. Pre-fractionator In this column, light naphtha is removed to reduce load on subsequent equipment i.e heat exchangers, heaters and column etc. There are 22 valve trays in the column. Feed enters at the 8th tray. The lighter vapours travels up in the column and at the top light naphtha vapours are condensed in a series if heat exchangers. Condensed liquid is collected in the reflux drum and the uncondensed vapours are released to the flare/GR fuel gas network. The top products i.e Light naphtha (containing LPG) goes to the stabilizer for LPG recovery. From 14th tray, side aphtha cut is withdrawn at 155 C in case of BH and SG crude. The side cut is stripped in the stripper and its bottom is pumped to naphtha pool or diesel pool via cooler. Top temperature of the column is to be maintained at about 11 C for imported, BH and SG crudes (temperature should be at least 15 C above dew point). Top pressure is maintained at 3.2 kg/sq.cm(g) by split range control with flare and hot vapour bypass. For maximizing recovery of light naphtha, stripping steam is introduced below 1st tray of column at desired rates. Crude Preheat-3 In this section, crude from pre-fractionator bottom at about 190 C is further preheated to 255-275 C before going to the heater. The crude from pump discharge goes to a set of heat exchangers where the crude is treated against LGO CR. Outlet crude flow is divided into two passes by DTC. Here crude exchanges heat with hot RCO. At outlet of both the passes crude is preheated upto about 275 C. At two outlets passes combine and go to the heater. Heaters (Furnaces) In the heaters, crude is further heated and partially vapourised by rising temperature from 275-370 C in case of imported and upto 355 C in case of BH/SG crude. Here, furnace is a box type, horizontal tubes, balanced draft furnace. Crude feed flows to the heater in four passes. The four passes join together and combine at the outlet to go to the distillation column. There are total 20 nos. of dual (oil and gas) fired burners and one gas burner in the heater.

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 Fuel oil pressure of 6.0 kg/sq.cm is maintained by the controller. The atomizing steam pressure to the burners is controlled by differential pressure controller. Fuel gas is supplied to the heater at about 3.4 kg/sq.cm. If fuel gas pressure falls below 1.8 kg/sq.cm low pressure alarm will sound in the control room and a safety shutdown valve SDV will automatically cut off fuel gas flow to the heater, thus eliminating the possibility of back fire. A return is provided on the fuel oil heater. A 1:1 ratio of fuel oil consumption to return is provided in the design to obtain a good control on firing and prevent congealing of the internal fuel oil (IFO) system. The globe valve provided on the IFO return line should be adjusted to give the desired circulation rate. For recovering heat from fuel gases, boiler feed water is circulated through BFW coils at convection section. Main Fractionator Partially vapourised crude from the heater outlet enters into the flash zone of the main fractionator column. In this column, there are total 40 nos. of valve trays. Feed enters at 6th tray from the bottom. From the flash zone, vapour portion goes up and while going up it comes into contact with colder liquid coming from the upper trays (called internal reflux) at each tray. In this way, heavier liquid falls below the next tray and the lighter vapours goes up in the next tray. Thus different fractions are separated in different trays depending upon the temperature of the tray. In the flash zone, unvapourised portion i.e RCO goes to the bottom as product. To help vaporizations and thereby more recovery of lighter products, stripping steam is given at the bottom of the column. If the transfer temperature is 370 C, flash zone temperature will be about 3 0 C. Reduced crude product is pumped out from the bottom of the column by RCO pumps under level control. The liquid from 7th tray is withdrawn entirely, measured by flow meter and put back into the column above 6th tray. The amount of flow is a measure of over flash, which is desirable for proper fractionation and recovery of the distillates. To maintain the heat balance in the column, circulating refluxes are withdrawn from the column, cooled in the heat exchangers and return back to the column. There are total three refluxes (HGO, LGO, KERO) and one top reflux is used. HGO product and HGO reflux are withdrawn at a temperature of about 320 C. LGO product and LGO CR are withdrawn at a temperature of about 275 C and return back at a temperature of about 225 C. KERO product and KERO CR are withdrawn at a temperature of about 200 C and return back at about 155 C. Above kerosene, Heavy aphtha is withdrawn at about 150 C. The top temperature and pressure is maintained at about 11 C and 0.9-1.0 kg/sq.cm respectively. From the top, naphtha vapour goes overhead condenser, the condensed liquid is collected in reflux drum from where a part goes as product to naphtha pool and other is routed to diesel pool. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 23

 The top pressure is maintained by the pressure controller with the help of flooding C/V located at the inlet of reflux drum and the reflux drum pressure is controlled by split range controller with C/V on fuel gas make up and flare line. Reflux drum pressure is maintained at 0.5 0. kg/s .cm(g). The column flash zone pressure and temperature are normally at about 1.1 1.3 kg/s .cm(g) and 3 0 C. Pressure safety valve releasing to L.P flare header are provided at the top of the column to protect it from over pressure. The column is cladded internally with 29 mm 410SS from bottom as a measure against corrosion. To control the flash point of products, Heavy Naphtha, Kero, LGO and HGO are steam stripped in their respective strippers. Stabilizer In the stabilizer, LPG separated from Light Naphtha is obtained as top product. The bottom product is stabilized Naphtha and goes to Naphtha pool. Feed to the stabilizer is pre-fractionator top product i.e Light Naphtha. It is first preheated to about 5 C. Columns bottom temperature is maintained at about 179 C by two reboilers. The columns top temperature is maintained at about C to maintain LPG weathering. The top pressure is maintained at 9.3 kg/sq.cm(g). At the top, LPG vapour goes to the condenser from where LPG in the form of liquid is collected in the reflux drum id pumped to the top reflux and to the run down. From the bottom of the column, naphtha first goes to the cooler. The cooler outlet goes to the Naphtha Caustic wash section. Naphtha Caustic Wash To remove corrosive sulphur compounds i.e Mercaptans, caustic wash is given. Main fractionators overhead Naphtha and AU-3 Naphtha combine together and go to Drum (D1) for caustic wash. For washing, caustic circulation pump is used. Caustic and Naphtha is mixed in the mixing valve before entering into D-1. In the vessel, caustic separates out and goes to the bottom and Naphtha overflows from the top. Continuous make-up and draining of caustic is done through level control valve. After caustic wash, Naphtha goes for water wash for removing any carryover of caustic. This is done in Drum (D-2) in the same way as in D-1. Here also fresh water is added continuously and the same amount is drained out. After water wash Naphtha goes to run down tanks. LPG Caustic Wash To obtain copper strip corrosion, the dissolved H2S and Mercaptans in LPG are removed by caustic wash. In this system, LPG run down is received in the surge drum from where it is pumped to caustic wash system. Drums D-2 and D-3 are used for LPG caustic and water wash respectively. About 50% caustic level is maintained in the flare knock out drum. For caustic circulation, pumps are used. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 24

 At the inlet of the flare knock out drum LPG and caustic are thoroughly mixed in the mixing valve and orifice mixture for removing H2S and Mercaptans. In the vessel, caustic separates out and goes to the bottom and LPG overflows from the top. CHEMICAL INJECTION FACILITIES De-emulsifier: De-emulsifier is injected in the crude pump suction to break oil and water emulsion in desalter. Normal injection rate is 4 to 5 ppm. However, if oil is observed in desalter drain water, de-emulsifier injection rate has to be increased. De-emulsifier chemical is brought in drums and offloaded into the vessel. The deemulsifier injection pumps are dosing pumps provided with a safety valve. The rate of injection can be varied by adjusting the knob on the pump. Caustic Solution: Caustic is injected in the crude pump suction, as water separation from oil in desalter becomes better in alkaline medium. For this, brine water pH is maintained at about 8.0 to 9.2. 3% wt caustic solution is prepared in the tank and injected by pump. At the desalter also, the same caustic is injected to neutralize the chloride salt. The chloride salt in the crude produces HCl (Hydrochloric Acid) at higher temperature. This HCl is highly corrosive to column overhead, vapour line and the reflux drum. Hence, caustic is injected to neutralize HCl to NaCl (sodium chloride). Finally NaCl goes out from bottom of the main fractionator along with RCO. Any left over HCl vapour goes to the top and finally comes along with sour water. Hence, if sour water chloride contents are reported more than 6 ppm, caustic injection post desalter has to be increased. Also sour water pH is to be maintained at 6.5 to 7.0 with the help of ammonia injection. Ammonia Injection: Ammonia solution is injected in the crude fractionating column overhead and in prefractionator column to neutralize highly corrosive acid HCl. Ammonia converts HCl to ammonium chloride (NH4Cl). About 1% strength ammonia solution is injected in the top vapour line and in the top reflux line. It is very important to know that the use of excessive ammonia will cause leak in the overhead condenser tubes. This is because ammonia reacts very fast with the brass metal and eats away the metal. Hence, sour water pH to be maintained strictly not more than 6.5. Ammonia is brought in the unit in cylinders. Water is received in the two solution vessels. Ammonia solution is prepared by injection of ammonia from ammonia cylinder into the solution vessel. A pressure gauge and safety valve are provided on the ammonia connection manifold. To prevent cooling and icing of the cylinders when preparing ammonia solution, a connection to spray water is provided. The solution vessels are provided with seal to minimize the loss of ammonia.

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 Corrosion Inhibitor Injection: Corrosion inhibitor is an organic chemical. It acts as corrosion inhibitor by forming continuously a monomolecular layer on the metal surfaces, by direct contact between metal and the corrosive elements present in the system. This is injected at the top f the vapour line of the crude fractionating column overhead and in the stabilizer column to protect vapour line and condenser. Normal injection rate of 4 to 6 ppm is maintained by the pump.

VACUUM DISTILLATION UNIT (VDU)

INTRODUCTION
The Vacuum Distillation Unit (VDU) of Gujarat Refinery was commissioned in 1979. The unit was designed to process 800,000 MTPA of RCO (50:50 North Rumaila and Arab Light). The unit produced Light Vacuum Gas Oil (LVGO); used as LDO blending component, Heavy Vacuum Gas Oil (HVGO); used as VBU feed and Vacuum Residue (VR); used as Bitumen Feed and VBU feed stock. After commissioning of FCC unit, HVGO from VDU is used as one of the feed components of FCCU. The yield of desired quantity of HVGO for FCC feed was very low. In 1994, low cost revamp of VDU was undertaken to meet the following objectives: To increase yield of Vacuum Gas Oil (VGO) of desired quality for FCCU feed stocks. To improve VR quality for BBU feed. To increase unit throughput. To increase energy savings by using redundant equipments from other projects. After revamp, VDU can process 880,000 MTPA of RCO. LVGO and HVGO are used as FCCU feed stocks. In addition, provision is made for routing LVGO to HSD as blending stock. In 1999, low cost revamp of VDU was undertaken to meet the following objectives. Throughput enhanced from 0.88 MMTPA to 1.2 MMTPA. To increase VGO yield and improvement of its quality. Reduce less than 370 C cut in VGO. Better bitumen feed quality. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 26

 After revamp VDU can process 1.2 MMTPA of RCO, Heavy diesel as top product used as HSD, LVGO+HVGO used as VGO for FCCU feed stocks. In the present column, there is a provision for withdrawal of four side cuts viz. Heavy diesel from top, LVGO, HVGO and slop distillate. Bigger wash zone provided to maintain VGO quality as well as VR quality to suite Bitumen production. In October 2004, VDU Air Pre heater (APH) revamp was done for increasing furnace efficiency and to recover heat from stack flue gas. FEED AND PRODUCTS The Vacuum Distillation Unit (VDU) is originally designed to process Reduced Crude Oil (RCO) obtained from Crude Distillation Unit (CDU) while processing imported crude. However, RCO obtained from various imported crude and indigenous crude (Bombay High, North Gujarat, South Gujarat mix.) has been processed successfully. By distilling the RCO under vacuum in a single stage column, it produces Heavy diesel, Light Vacuum Gas Oil (LVGO), Heavy Vacuum Gas Oil (HVGO) and Vacuum Residue (VR). Slop cut (distillate between HVGO and VR) production facility has been provided since 1988. UTILITIES AND THEIR CONSUMPTION Sr. No. 1 2 3 4 5 6 \ Utility LP Steam, T/hr MP Steam, T/hr Cooling water, cu.m/hr DM water Fuel Oil, T/hr Fuel Gas Consumption Uses 2.5 10.0 1400 10.0 1.7 300-800 Stripping Ejector, Atomizing, Soot blowing, Velocity, Snuffing and Emergency Condensers, Coolers and Pumps Steam generation and Tempered water

PROCESS DESCRIPTION Brief Description Cold RCO is received in the feed surge drum under level control from storage tanks. Hot RCO may be received from the Crude Distillation Units. RCO is pumped by charge pumps to a series of preheat exchangers and then to furnace from where feed goes to the main column. In the 1st heat exchanger LVGO exchanges heat with RCO where RCO is in the shell side and LVGO+Pump Around (PA) in the tube side. In the 2nd heat exchanger HVGO withdrawn from column heats RCO in the shell side. Then in the next heat exchanger slop cut exchanges heat with RCO followed by heat exchange with vacuum residue (VR). At the end of the preheat train, feed is heated upto 305 C in case of hot feed and upto 292 C in case of the cold feed. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 27

 Preheated RCO is split into two passes and introduced to Vacuum Heater i.e furnace under pass flow control for each pass. MP steam is injected in each pass to increase velocity and encourage vapourization of feed in the coils. Coil outlet temperature of 395-39 C is maintained at the furnace outlet. Partially vapourized RCO is introduced in the flash zone of the vacuum Column. LP steam is superheated upto 350 C in the convection coils of furnace and used as stripping steam in the stripping section of the vacuum column. Vapourized RCO along with steam rises through the vacuum column and is fractionated into four nos. of withdrawals. 1st withdrawal is Heavy Diesel which after exchanging heat with feed in the heat exchangers is cooled to 55 C. One part is fed to the top of the column as cold Circulating Reflux (CR) and another part is fed as Internal Reflux (IR). Balanced Heavy Diesel is sent to the storage under flow control.

2nd withdrawal is HVGO+PA by pumps. HVGO is bifurcated into two streams. One stream is returned as IR to column and another stream is returned to the column as cold Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 28

CR after exchanging heat with RCO. HVGO also exchanges heat with water and generates steam in one bundle. Subsequently, it is cooled in HVGO cooler and sent to the storage under flow control. 3rd withdrawal is LVGO by pumps. One part is returned as IR along with cold HVGO and another part as cold CR. Third part goes with HVGO rundown as VGO (Vacuum Gas Oil). VGO may be routed to FCCU (Fluidized Catalytic Cracking Unit), VBU (VisBreaker Unit), LSHS and slop. 4th withdrawal is the slop cut through chimney trays by pumps. Slop cut withdrawn is routed to LSHS/FO/LDO pool. A stream of slop cut is returned back to the column as IR in flash zone. Vacuum Residue (VR) is withdrawn as column bottom by pumps. After preheating the feed in a series of heat exchangers, a quench stream is routed back to the column to maintain bottom temperature of 355 C to avoid coking in the column boot. Further VR goes to the LP steam generator an gets cooled upto 150 C. VR is routed as follows: Before getting cooled Hot VR to BBU under flow control Hot VR to VBU under flow control Hot VR to VR burning facility Hot VR to IFO drum

After getting cooled Direct VR injection in BBU After cooling in the tempered water cooler, VR is routed to storage as 130 C Tempered water, required for cooling is obtained from tempered water tank. Hot tempered water is cooled with cooling water in the tempered water cooler to maintain temperature of hot circulating tempered water. The desired vacuum is obtained by pulling vacuum by multistage ejectors, precondensers, intermediate condensers, after condensers and hot wells. Detailed Description The Vacuum unit consists of the following sections, viz. Surge Drum and Preheating Section, Vacuum Heater, Vacuum Column and Product Cooling, Vacuum Overhead System, Steam Generation and Tempered water System. The detailed description of the various sections and some important parameters are described below: Surge Drum and Preheating Section The surge drum is a horizontal vessel. The feed to the unit consists of three streams of Reduced Crude Oil (RCO) at about 120 C. Reduced Crude is also drawn from the storage tanks at about 0 C through pumps and it maintains the level in the surge drum. A pressure of 1.0 kg/sq.cm is maintained in the surge drum. The pressure controller on the surge drum acts on the two control valves on the split control. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 29

 One of them maintains pressure in the surge drum by admitting fuel gas. If the pressure rises beyond the desired level 2nd valve opens letting down the pressure to the flare. A safety valve with spare is provided to protect the vessel against over pressure. The line from feed surge drum to flare is routed through a knock out pot to avoid any liquid from entering the flare header. An LP steam coil is also provided in the surge drum to maintain the temperature. The reduced crude charge pumps takes the suction from feed surge drums. A pressure indicator and a low pressure alarm are also provided on the common discharge line. The reduced crude gets progressively heated from 120 C to 300 C by LVGO+PA in the exchanger then by HVGO and then followed by HVGO+PA in the exchanger. A slop cut paralleled with VR is followed. Temperature indicator is provided on the line to the Vacuum furnace which measures the outlet temperature of the reduced crude. Each of these exchangers is provided with isolation and bypass valves both in the shell and tube side. The exchangers are also provided with temperature and pressure gauges so that the performance of each exchanger can be evaluated. The reduced crude side of these exchangers is provided with TSVs (Temperature Safety Valves) to provide thermal relief in case the reduced crude side of an exchanger is double blocked with the hot stream in commission. Vacuum Furnace Reduced crude enters two passes of the vacuum heater through control valves. Low flow alarm is provided for the two passes. Pressure gauges are located at the inlet of the each pass of the furnace and at the entire external crossover of the oil coils. Temperature indicators are also provided in the external crossover. To increase the velocity of the reduced crude in the coils and to avoid coking, MP steam is injected in both the passes. The partially vapourized stock leaving the heater is transferred into the flash zone of the vacuum column. A pressure gauge with temperature indicator and controller is provided in the transfer line. Transfer line temperature is adjusted to about 395 C to maintain flash zone temperature of about 375 C. Vacuum Furnace is provided with Air Pre Heater to improve the furnace efficiency along with FD fans and ID fan. In addition to the oil coils, the convection section has two more coils, one for superheating steam and other for producing steam from boiler feed water. The superheating coil is provided with safety valve and venting facility at the outlet. 16 soot blowers are provided in the convection section to remove soot and ash deposits on the tubes.\

Vacuum Column and Product Routing Vacuum Column:

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 The function of the vacuum column is to permit relatively low temperature fractionation of the reduced crude into Heavy Diesel (HYD), Heavy Vacuum Gas Oil (HVGO) and Light Vacuum Gas Oil (LVGO). This is made possible by vacuum and partial pressure effects of the steam. Vacuum columns have different diameters. As the column operates under vacuum, vapour velocities are high. Sections where vapour velocities are low are smaller in diameter to affect cost savings. The tower has 5 packed beds with chimney trays above the flash zone in the rectification section and 5 trays below in the stripping section. Product Routing: Heavy Diesel PA are drawn off from chimney tray at a temperature of 135 C by pump. It is routed to a heat exchanger where it is cooled to 5 C. At the outlet of the cooler it splits into PA return and Heavy diesel to storage. On the PA return line a three way valve is provided which bypasses one heavy diesel PA from heat exchanger inlet to control the temperature of the pump around return 5 C. The column top temperature at 0 C is achieved by temperature controller, which adjusts the flow of PA to the column. Flow of heavy diesel to storage is controlled by the flow controller. It can be routed to LDO/HSD/DHDS storage tanks or to FCCU or to furnace oil header. Before entering the tower the PA flows through a strainer which is provided with block and bypass valves. Vacuum Overhead System A two stage steam ejector maintains vacuum on the tower with surface condensers. Steam, vacuum overhead gas oil and a small amount of light hydrocarbons produced by cracking pass out of the top of the vacuum tower into a pre-condenser where most of the gas oil products and stripping steam is condensed. Non-condensable gases are sucked by steam ejector and are partially condensed in the after condenser. Non-condensable from after condenser escapes to atmosphere at higher elevation after passing through liquid seal in the hot well. This is to avoid ingress into the column during steam failure. A fuel gas back-in line is provided near the inlet of Vacuum overhead Pre-condenser for start-up purposes. Aqueous ammonia is injected in the overhead vapour line at the top to control the pH of sour water between 6.5 to 7.0 in Vacuum Condensate Drum (hot well). Preparation and dosing facility of aqueous ammonia solution is provided in VBU unit. Cooling water circulates in series or parallel through the condensers. While in series, it enters pre-condenser and from outlet splits into two streams; one stream flows through inter-condenser and the second through after condenser. While in parallel, the cooling water enters independently the pre-condenser and water from the inlet of HVGO cooler enters the inter and after condensers in parallel.

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 Condensate from the condenser shells drops through the sealed dip legs into the hot well where the oil and water separate. Hot well is a horizontal vessel consisting of two sections separated by a baffle. The pumps in the vacuum unit that take suction from the vacuum tower are served by a vacuum vent system. The vents from the various vacuum pumps are connected to a header, which enters below the first tray of the rectification section in the vacuum tower. The vent system is necessary so that a vacuum can be pulled on a pump casing before the suction valve is opened. The following pumps are served by the system: Heavy Diesel + PA pump HVGO pumps Vacuum Residue and Quench pumps HVGO PA Slop Distillate pumps LVGO + PA-2 pump Tempered Water System In this system the boiler feed water (BFW) is used in a close circuit for cooling purposes. This particular cooling system has been provided for vacuum residue, slop cut and bitumen, which should not be cooled below its pour point. The system consists of surge drum, three circulation pumps, three tempered water product coolers viz. Vacuum Residue cooler, Slop cut cooler and Bitumen cooler latter located in Bitumen unit and one tempered water exchanger. Boiler feed water make-up is provided to make up for evaporation losses. Due to evaporation losses, pH of tempered water comes down and becomes acidic in nature. pH of tempered water is checked manually in intervals. If pH comes down, Morpholine chemical addition facility is also provided. Tempered water or hot water is drawn from the surge drum at a temperature of 5 C and routed to exchangers where it cools the product. Tempered water gets heated to 5 C in this process. It is again cooled to 5 C by cooling water before it enters the surge drum. Steam can be injected into the surge drum in case the water temperature drops below 0 C. Waste Heat Boiler There are two waste heat boilers in VDU. The 1st waste heat boiler is provided to remove heat from LVGO and HVGO streams and produces LP steam. It consists of a shell with two tube bundles. One bundle caters for LVGO and the other for HVGO. LVGO enters at a temperature of 210 C and leaves at a temperature of 175 C. HVGO enters at 210 C and leaves at 150 C. Boiler feed water at 103 C is fed onto the shell side of the boiler. Two safety valves are provided to safeguard the boiler from over pressure. The 2nd waste heat boiler is provided to remove heat from VR and produces LP steam. VR flows in the tube side it gets cooled to 175 C from 210 C. Boiler feed water at 103 C is fed to the boilers shell side. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 32

Continuous and intermittent blow down from both the boilers are fed to the blow down drum which is vented to the atmosphere. This controls the total dissolved solids in the boiler water. The oil side of the waste heat boiler is provided with block valves and bypass to facilitate shut down for inspection.

VIS-BREAKER UNIT (VBU)

INTRODUCTION
The Vis-breaker Unit was originally designed to process 1.0 MMTPA of atmospheric residue, vacuum gas oil and vacuum residue from a 50:50 blend of Light Arabian and North Rumaila crudes for the production of fuel oil. In the year 1993, the unit was revamped with introduction of soaker technology for increasing its capacity from 1.0 MMTPA to 1.6 MMTPA using 100% North Gujarat or Imported Crude vacuum residue as feed stock for the production of fuel oil. As per requirement, fuel oil is also produced by using vacuum residue as feed stock and then adding cutter stock. In conventional coil cracking, the residence time in the coil is less, hence the desired conversion is achieved by maintaining higher ( 70 C or more) cracking temperature. However, in soaker technology, the same amount of conversion is achieved at much lower temperature ( 55 C or less) by providing adequate residence time at its cracking temperature in the Soaker Drum. Cracking starts in the heater coils and this cracking reaction is allowed to continue in the soaker drum. Thus both temperature and residence time are very much important for achieving desired degree of conversion. At the outlet of soaker, a back pressure control valve maintains sufficient back pressure (about 12.0 kg/sq.cm) in the soaker drum and in the heater coils so that the reaction mixture remains in the liquid phase and thus helps in maintaining adequate residence time for desired conversion. The unit is designed for normal conversion of 5.7 wt% of feed with the production of stable fuel oil. Excess conversion results in instability in the fuel oil and viscosity starts increasing. Instability occurs due to separation of asphalteness. In the soaker Vis-breaker, since cracking temperature is maintained lower as compared to that of coil cracking, the rate of coke deposition in the heater coils is less and fuel consumption is also less. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 33

 The unit consists of two pass cracking heater, soaker and a fractionator. The products of the units are fuel oil, VB gas oil, VB Naphtha and fuel gas. FEED AND ITS SPECIFICATIONS Atmospheric Residue Vacuum Gas Oil Vacuum Residue from a 50:50 blend of Light Arabian and North Rumaila Sr. No. 1 2 3 4 Specification North Gujarat VR 0.994 +54 0.29 Imported VR 1.029 +54 5.13 2524 Bombay High VR 1.015 +78 0.77 1396 North Gujarat RCO 0.940 +39 0.19 63.5 Imported RCO 0.973 +15 3.91 74

Specific Gravity Pour Point ( C) Sulphur (wt %) Kinematic 1540 Viscosity at 100 C (cst) Wax content 22.3

PRODUCTS Fuel Gas VB Naphtha VB Gas Oil VB Tar UTILITIES AND THEIR CHARACTERISTICS The pressure and temperature of the utilities at the battery limit of the unit are: Sr. No. 1 2 3 4 5 6 7 8 9 10 Description LP Steam MP Steam Re-circulating water supply/return Boiler feed water Fuel Oil Fuel Gas Service water Service air Instrument air Flushing oil Pressure (kg/sq.cm) 4.5 10.0 5.5/3.5 22.5 10.0 3.1 3.5 7.0 7.5 8.0 C) 165 230 33/45 190 80-271 35-50 Ambient Ambient Ambient 40

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PROCESS DESCRIPTION Brief Description The various components of the feed are first preheated in the heat exchanger to about 150 C and then received in the surge drum. The combined feed stock is pumped by the Vis-breaker charge pump in to the heat exchanger set to about 315 C and the feed suction goes to the suction of the charge booster pump. The hot feed from the discharge of the booster pump is routed to the two passes of the Vis-breaker furnace under flow control. The VB furnace provides the heat required for preheating and cracking reactions of the feed is heated upto 5 C. At the furnace outlet, feed enters the soaker drum from the bottom and comes down from the top. In the soaker drum, cracking reactions are allowed to continue at its cracking temperature by providing residence time of about 20 minutes for the desired conversion. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 35

 At soaker outlet, one back pressure controller maintains a constant back pressure of about 12.0 kg/sq.cm in the soaker and in the heating coils so that the reaction mixture remains in the liquid phase and thereby increases its residence time for better conversion. The hot reaction mixture at the soaker outlet is uenched by injecting cooled Vis-breaker tar to about 3 C for arresting further cracking reactions. The quenched effluent from the soaker outlet enters the VB fractionator where it is separated into various products. In the bottom of the VB fractionator, steam is introduced to remove lighter fractions. As and when required, slop oil from GRE tanks is also fed to VB fractionator along with gas oil in the transfer line for stripping out the light ends. VB tar is removed as bottom product. The bottom product goes to the fuel oil tank or LSHS (Low Sulphur Heavy Stock) tank depending upon the feed quality. One side draw i.e VB gas oil can be routed to HSD, LDO, DHDS or LSHS. However it is normally routed to LDO/DHDS. To maintain the thermal condition of the column and heat recovery, one gas oil circulating reflux has been provided. The overheads from the VB fractionator are VB Naphtha and gas. Gas is sent to the fuel gas network. Naphtha is stabilized in a debutanizer and is sent to the Naphtha Merox Unit for removal of the sulphur compounds and finally to storage. Detailed Description Feed Supply and Preheating The feed to the Vis-breaker unit consists of Cold VR from storage, VR from VDU plant, RCO from storage tanks, Hot RCO from CDU, HVGO of VDU unit and RCO from AU-3. Among all these feed normally almost 100% VR is used as feed from different unit during LSHS/FO run. All the feed from different sources is first preheated in the heat exchangers to about 150 C and then goes to the feed surge drum. The drum level is maintained by varying the flow of clod feed. In case of hot feed, it is directly routed to the surge drum skipping the first set of heat exchangers. The feed drum pressure is maintained by Split range control. Surge drum pressure is maintained at 2.5 kg/sq.cm. VB charge pump (screw pump) routes the feed through VB feed via VB tar exchangers. The feed is heated upto about 315-320 C. The VB charge booster pump takes suction from the exchangers outlet and routes the feed to the two passes of the VB furnace. The flow in the passes is controlled by flow controllers. VB Heater Originally VB heater was natural draft furnace. In the soaker revamp, the convection section height of the furnace has been increased to accommodate more number of hydrocarbon preheat, and the other coils and in view of this two nos. ID fans have been provided for maintaining draft level of the heater. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 36

 The radiation section of the heater is twin cell type where each cell is further divided into two sections. In each section burners are fired along the bridge wall. Total 64 nos. combined oil and gas burners have been provided with pilot gas burner. The convection section is common which houses the hydrocarbon preheat coils, steam-superheating coils, BFW steam generation coils and BFW preheat coils. The radiation section houses cracking zones of the coils. One Temperature Safety Valve (TSV) has been provided at the outlet of the preheat coils. The coils are also provided with a safety valve with spare to protect the coils against overpressure. The feed is preheated in the convection section and then it passes to the radiation zone. The VB feed to the heater flows in two passes. Combination of oil and gas burners are used. There are soot blowers in three different levels of the convection zone of the furnace. The soot blowers are electric motor driven and MP steam is blown from these blowers to blow out loose soot from the studded tubes. Soaker The soaker drum is a hollow vessel, it provides adequate residence time to complete the desired cracking reaction by the time the feed mixture comes out at the soaker outlet from the top. Partially cracked feed at the outlet of the heater enters the soaker drum from the bottom. At the inlet, feed distributor is there for uniform distribution of the feed along the horizontal cross section of the vessel. This helps to eliminate channeling and the stagnant zone in the vessel. To measure the temperature profile in the soaker, thermocouples have been provided. 15-20 C drop in the temperature is observed from bottom to top due to endothermic nature of cracking reactions. If the temperature drop is less, it indicates les amount of cracking. To maintain the reaction mixture in liquid phase in the soaker drum as well as in heater coils to have better residence time for cracking one back pressure control valve has been provided at the soaker outlet which maintains about 12.0 kg/sq.cm back pressure in the soaker and in the heater coils. At the soaker outlet the cracked mixture is uenched with cold VB tar at 250 C for bringing down the temperature from 20-3 C. Quenching is done to stop further reaction. During the course of reaction, certain amount of coke also deposits along the inside surface or soaker drum. To empty out the soaker vessel during normal or emergency shutdown, one soaker pump outline from the soaker bottom inlet line to the fractionator bottom outlet line has been provided with control valve located near the soaker bottom. To avoid coking up of the pump out line, provision is there for continuous injection of flushing oil. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 37

VB Fractionator: The quenched effluent from the soaker outlet enters the VB fractionator. It separates into VB tar as bottom product, VB gas oil as side product, naphtha and gas as overhead products. The fractionator has 2 trays and the feed enters into the flash zone at about 375 C. In the bottom section, VB tar product is steam stripped. Superheated steam at 10.0 kg/s .cm and 370 C enters the column for stripping of which the flow is controlled and measured by controllers. The VB fractionator bottom product at 350 C is passed through coarse tar filters and then through the fine tar filters. This VB tar is cooled by passing it through the exchangers and thereafter divided into three streams. One portion goes to the soaker top as quench, the second portion goes to the fractionator bottom as bottom quench and the third portion under level control of the fractionator is routed to the MP steam generator. As side product VB gas oil is withdrawn at about 250 C. Gas oil is withdrawn to the stripper where lighter material from the gas oil is stripped off with the help of the superheated stripping steam. Gas oil from the bottom of the stripper goes to the heat exchangers and is further cooled and sent to either LDO or HSD or FO/LSHS or DHDS pools. Gas oil is withdrawn into three streams. One stream is used as heating medium to debutanizer reboiler. Second stream is used to MP steam. Gas oil after getting cooled returns as CR. Third stream directly goes as tray wash to avoid coke depositions and chokages. The overhead vapours from the fractionator at 1 7 C are first partially condensed in the Air-Fin cooler and then it goes to final condenser. Condenser outlet is separated in the reflux drum. The sour water from the reflux drum is routed to sour water stripper feed drum. A portion of the condensed hydrocarbon liquid is pumped back to the fractionator as top reflux. Debutanizer Naphtha from the VB fractionator reflux drum is fed into the debutanizer. The overhead product at 5 C goes to the condenser and the condensed liquid is collected in the reflux drum. The debutanizer pressure is maintained at about 7.5 kg/sq.cm. Debutanizer bottom goes temperature is maintained about 1 0 C by the reboiler where the gas oil CR stream is used as heating medium. The debutanizer bottom goes by its own pressure to the exchanger and then to the cooler where it is cooled to 0 C. From the cooler the debutanized naphtha goes through flow controller and is further routed to the Naphtha Merox Unit for treatment.

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BITUMEN BLOWING UNIT (BBU)

INTRODUCTION
The Bitumen Blowing Unit (BBU) under Gujarat Refinery Expansion was designed to process Vacuum residue obtained from 50:50 blend of North Rumaila and Light Arabian crudes to process 200,000 metric tones per year of 80/100 pen, 25,000 metric tones per year of 60/70 pen and 25,000 metric tones of 30/40 pen bitumen product. The unit was designed to operate in blocked out operation to produce the above three grades of bitumen. The major equipments of Bitumen Unit are located in the Vacuum Unit plot area and a no. of common utility systems serve both these units. The chief advantage of the Biturox process is the flexibility in the feed stock that can be used for the production, a wide range of other materials like Propane de-asphalted and Vis-breaker residues blended with vacuum gas oil/extract can be used in a proper blending rate. The biturox unit is designed for continuous operation and the capacity range of the unit covers 60-100% of the designed capacity. FEED AND ITS SPECIFICATIONS Persian Gulf crude or a mixture of Persian Gulf and North Gujarat crude will be used as feed stock. As design feed, the mixture of Persian Gulf and North Gujarat crude was selected for the design of the Biturox Reactor. A longer retention time was required for the production of S65 using vacuum residue Sr. No. 1 2 3 4 5 Specification Unit VR Persian Gulf VR Persian crude Gujarat crude 155 40.5 1.0198 Kg/cu.dm 1.0259 234 41.0 0.9995 1.0056 Gulf/North

Penetration index Softening point Specific gravity Density at 15 C

mm/10 C

Flash Point C 320 316 from the mixture of Persian Gulf and North Gujarat crude.

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PRODUCT AND ITS SPECIFICATIONS The product obtained is three grades of bitumen. S90 grade bitumen------------------- 99% yield S65 grade bitumen------------------- 98.5% yield S35 grade bitumen------------------- 97.5% yield Sr. No. Specification Unit S90 grade S65 grade 1 Specific gravity 0.99 0.99 2 Water content wt% 0.2 0.2 3 Flash point C 175 175 4 Softening Point C 35-50 40-55 5 Penetration index mm/10 80-100 60-70 UTILITIES AND ITS CHARACTERISTICS Sr. No. 1 2 3 4 5 6 7 8 9 Utility LP steam MP steam Boiler feed water Fuel gas Fuel oil Tempered water Circulating cooling water Supply/Return service water Instrument Air C) Pressure (kg/sq.cm) 4.0 10.0 14.5 1.7-2.1 10.4 5.0 4.5/2.5 2.5 7.0

S35 grade 0.98 0.2 175 50-65 30-40

151 230 105 35-50 80-271 65-85 33/45 Ambient Ambient

PROCESS DESCRIPTION Brief Description The unit shall receive hot feed (vacuum residue) from the vacuum unit directly at a temperature of about 2 0 C and cold feed from storage. hen vacuum unit is shutdown, bitumen unit will receive the entire feed from storage at 120 C. The feed enters the converter at a temperature of 2 0 C. This is achieved by heating the feed in the heater. The vacuum residue is blown by air in the biturox reactor at temperature of around 2 0 C. Since this is an exothermic reaction, the evolved heat is to be removed. This is accomplished by injecting water along with Process air and steam into the reactor at the top. The blown bitumen is pumped from the Biturox reactor under level control through the steam generator and the bitumen product rundown cooler. The hydrocarbon vapours, steam and the unreacted air from the reactor overhead go to the water quench drum where hydrocarbons are condensed along with some water. The uncondensed gas is burnt in the incinerator through the water seal drum. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 40

 The condensed hydrocarbons and the water are separated in the settling drum from where the oil is routed to slops and the water drained to oily sewer. Detailed Description The following subsections describe the process flow of the Bitumen Unit in detail: Feed Heating System The feed to the bitumen unit consists of the hot vacuum residue taken directly from the vacuum unit and cold vacuum residue from the storage. The hot VR enters the bitumen unit at a temperature of about 2 0 C. The flow of the feed is controlled by a valve. The cold vacuum residue from the storage is pumped by feed pumps to the furnace where the vacuum residue is heated to a temperature of about 215 C. The temperature of the feed is maintained at 232 C. The combined feed is then routed to the biturox reactor. Steam Generator Steam generator is a horizontal kettle type exchanger having two tube bundles in a single shell. Heat exchange of the bitumen rundown is carried out through both the bundles with Boiler Feed ater to reduce the combined feed temperature to 200 C. Boiler feed water flows on the shell side under the level control of which actuates the control valve on the boiler feed water line to the steam generator. Low pressure steam is generated in the shell side. Steam generated in the shell joins the low pressure steam header running on the vacuum-bitumen unit pipe rack. Flow indicator is provided to measure the amount of steam generated in the exchanger. Steam disengagement facilities are provided in the shell to avoid carryover of water with steam. Bitumen Feed Pumps The bitumen unit gets its cold feed from the vacuum residue storage tanks at a temperature of 120 C. The bitumen feed pumps take suction from the storage tanks through suction line. One pump is running normally and the other serves as spare. The feed pump discharges vacuum residue at a pressure of 8.8 kg/sq.cm, which flows to the bitumen heater for heating to the reaction temperature. A slip stream of vacuum residue from the discharge of the pump goes as a feed component to the Vis-breaker unit. Bitumen feed pumps are screw type steam jacketed pumps. Each pump is fitted with a built in relief valve for protection against over-pressure. Bitumen Heater The vacuum residue from the discharge of the feed pump is to be heated in the Bitumen Heater from a temperature of 120 C to the reaction temperature of 215 C. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 41

 Bitumen heater is a vertical cylindrical type furnace having a single helical coil in the radiation zone. The heater is provided with three oil burners having self-inspiriting gas pilots. The temperature of the feed at the outlet of the heater is controlled by temperature controller, which is cascaded to the fuel oil pressure controller actuating the control valve on the fuel oil line to the heater. The bitumen heater has three main burners, which can be fired by oil only. Each main burner is provided with a gas pilot. The burners should be operated to provide fire, which are uniform in length and size as can be obtained. It is normally desirable to fire all three burners even when running at reduced capacity to ensure uniform heat distribution to all tubes. Biturox Reactor The reactor unit, where biturox process occurs, consists of three main components: Biturox reactor Agitator, with three stages of disc mixers Guiding cylinder, located concentric to the shell and containing two coalescing plates, each one is located under the middle disc mixer and the other under the upper disc mixer Measured amounts of feedstock, air and water are simultaneously fed into, and processed within the reactor unit. Compressed air is fed into the guiding cylinder through four vertical air injection pipes and flows down through the pipes to the bottom of the reactor where it is blown into the incoming feed. As air injection pipes are large in diameter, the air bubbles created at the bottom of the pipes are large and, as such, minimize the amount of available oxygen at the air inlet, which prevents overheating and the coke formation at this point. Overhead System of the Biturox Reactor Off-gases from the biturox process contains N2, residual O2, water stream, CO, CO2, H2S, SO2 and the hydrocarbons with the average molecular weight of C17 kg/kmol. To prevent the deposits in the off-gases line, make-up water (BFW) will be injected into the off-gases pipe. Due to vapourising of BFW the temperature of the off-gases will be reduced approximately to 170-1 0 C. As a result of the off-gases cooling, a part of the hydrocarbons will condense from the off-gases and wash the pipe. The amount of injected BFW is controlled with the flow control. Temperature meter measures the temperature of the off-gases after injection, which is located upstream of the pressure control valve. The off-gases are led by pressure control valve to the quench to the existing scrubber section for further cooling of the off-gases and the separation of the condensed hydrocarbons. The uenched off-gases from the uench drum passes through a water seal drum where the temperature of gases is reduced to 9 C. This drum is located on the top of the quench drum. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 42

 Water is injected into the drum and a seal is maintained by a gooseneck seal. The offgases from the water seal drum is routed to the incinerator. Incinerator The off-gases from the water seal drum is routed to the incinerator through flame arrestors. Normally one pair of flame arrestors is on the line, the other pair will remain as standby. The off-gases then enters the incinerator through four nozzles where it is burnt. The incinerator is a vertical cylindrical type furnace provided with one fuel gas burner. The box temperature in the incinerator is controlled by a temperature controller, which resets the pressure indicator controller which in turn regulates the fuel gas pressure to the burner. If the fuel gas pressure falls a low-pressure alarm sounds in the control room and the shutdown valve will automatically cut off fuel gas to the incinerator thus eliminating the possibility of a back fire. In addition in case of flame failure in the incinerator an ultra violet sensing element will sense it and sound flame failure alarm in the control room and activates the shutdown valve and shut off fuel gas flow to incinerator. Bitumen Product Routing The produced product is discharged from the reactor by the product pumps. The discharge of the product is controlled by the level control and a selector switch is provided at DCS for selection. A part of the product leaving the reactor is circulated on the pressure control from the product pumps back to the feed line of the reactor. The product is led to the steam generator and the bitumen trim cooler will be used to cool the product to a storage temperature.

PROCESS VARIABLES Temperature As the process is an exothermic one, it is important, that the operating temperature within the reactor will be tightly controlled. This is accomplished by injecting of process water into the air pipes. o As the water vapourizes in the air pipes, it cools the content of the reactor making it possible to maintain precise temperature control. In principle the temperature in the vapour space of the reactor is at least 50 C less than the bitumen temperature in normal operation. In case of high temperature in the vapour space, low-pressure steam can be fed into the vapour space for quenching purposes. The quench steam valve is operated by hand and approached from the ground surface at the steam header of the reactor. Pressure To prevent an over pressure of the reactor, a rupture disc in combination with safety valve at the top of the reactor is provided. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 43

 The set pressure of the safety valve is related to the design pressure of the reactor. The set pressure of the rupture disc is lower than the set pressure of the safety valve, so that it will be possible to adjust the correct pressure after bursting of the rupture disc before the set pressure of the safety valve will be reached. The normal operating pressure range ends at 90% of the bursting pressure of the rupture disc. If this percentage is exceeded, the rupture disc will be damaged and may burst under the normal operating pressure. The burst of the rupture disc is indicated by a pressure gauge with an alarm high signal, located between rupture disc and the safety valve. Liquid Level The level in the reactor is indicated and controlled by a liquid controller which affects the level valve in the discharge line of the product. A redundant level control based on a measurement of a differential pressure of the liquid column in the reactor is provided. During operation four temperature transmitters, indicating important points of the liquid level, additionally supervise the liquid level. The level indication is based on the temperature difference between the liquid and gaseous phase.

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GUJARAT REFINERY SECONDARY PROCESSING FACILITIES (GRSPF)

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FEED PREPARATION UNIT (FPU)

INTRODUCTION:
Feed P r e p a r a t i o n U n i t ( FPU), a p a r t o f G u j a r a t R e f i n e r y Secondary Processing Facilities (GRSPF) was originally designed with a throughput of 1.66 MMTPA of RCO. The primary function of this unit was to produce 700,000 T/year of vacuum gas oil for feed to FCCU along with vacuum diesel and vacuum residue. Later on, it was decided to revamp the Feed Preparation Unit (FPU) to meet the increased VGO feed requirement in Fluidized Catalytic Cracking Unit (FCCU), which was also revamped, to 1.5 MMTPA.

FEED: mixed RCO (MAX) PRODUCTS:

1. Heavy Diesel 2. Vacuum Gas Oil

PROCESS: The process is same as that for vacuum distillation unit of GRE. Four
side draw products are obtained from the column: 1) Heavy diesel is obtained as the topside draw product. 2) Light vacuum Gas Oil (LVGO) is obtained as the second side draw product. The LVGO pump around is used to generate LP steam after which it is returned to the column. 3) Heavy vacuum gas oil (HVGO) is obtained as the third side draw product. A pump around reflux is also drawn off at this point. The HVGO product exchanges its heat with RCO after which it is used to generate LP steam. 4) Slop Distillate is drawn as the fourth side draw product. The recycle stream is also drawn off at this point and is mixed with RCO at the entry to the Vacuum furnace. The Slop Distillate mixes with Vacuum Residue downs tream of MP steam generator or cooled in slop distillate cooler and sent to GRE FO Pool.

(**This Process Is Same as GRE VDU)

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FLUIDIZED CATALYTIC CRACKING (FCC)

INTRODUCTION: During 80's with increased processing of the North Gujarat and
Bombay High Crudes, the production of LSHS had gone up. This increased production of LSHS should have been suitably disposed off to enable the refinery to operate at its maximum throughput for meeting requirements of the petroleum products. This LSHS, which is presently being supplied as fuel for burning, has a good potential of being refined into high priced distillates, which are in great deficit in our country. The steep increase in the prices of crude oil and petroleum products in the past few years and governments policy of conservation of petroleum energy has changed the situation totally and it became necessary to review the utilization of LSHS more economically and profitably. Based on the above consideration, the various alternatives of Secondary Processing Schemes were examined and it was decided to install Fluid Catalytic Cracking Unit (FCC) at Gujarat Refinery. In 1982 Gujarat Refinery FCC Unit was commissioned with a capacity of 1 MMTPA.

HISTORY OF FLUIDIZED CATALYTIC CRACKER: Cracking is a phenomenon in

which large oil molecules are decomposed into small lower boiling molecules. At the time certain of these molecules, which are reactive, combine with one another to give even larger molecules than those present in the original stock. The more stable molecules leave the system as cracked gasoline and reactive ones polymerize forming fuel oil and even coke. Although primary objective in development of the cracking process had been to get more and more of gasoline, all other oils having boiling ranges intermediate between fuel oil and gasoline is also produced. The originally developed process of cracking was Thermal Cracking. Use of catalyst for cracking was first investigated by HOUDRY in 1927. Catalytic cracking has many advantages over Thermal cracking viz. 1) Catalytic cracking gives more stable products 2) For corresponding yield and quality of gasoline, catalytic cracking unit operates under less severe conditions 3) Catalytic cracking gives high-octane gasoline (viz.91-94 octane). 4) It yields less gas viz. Methane, Ethane and Ethylene. 1) BATCH PROCESS: The first commercial Catalytic Cracking Unit was put into operation in 1936. It was a Fixed-bed Catalytic Cracking Unit. It consisted of a series of chamber / reactors, wherein one of them is on-stream, the others will be in the process of cleaning, regeneration etc. This type of process has a disadvantage of being an intermittent process having a high initial investment and operating cost. 2) CONTINUOUS PROCESS: The advantages of continuous process led to the development of the idea of a moving bed catalyst. Examples of this type are Thermofor Cracking Thermofor Catalytic Cracking and Houndry Airlift processes. In the Thermofor Catalytic cracking, the palletized catalyst was conveyed between the reactors and regenerator by means Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 47

of Bucket Elevators. Higher investment by capacity limitations of Elevators/Air lift systems together with other engineering and process difficulties led to the development of latest concept in moving bed catalytic cracking i.e. Fluidized Catalytic Cracking.

FLUIDIZED CATALYTIC CRACKING: The radical development was made by

Standard Oil Co., New Jersey, M.W.Kellogg and UOP in early 19 0s in which the catalyst in the form of fine powder was held in suspension in gas stream. It was found that by carefully controlling the catalyst particle size and the velocity of gas moving through it, a fluidized bed of catalyst would form which has the properties of liquid. In the fluidized system, finely powdered catalyst is lifted into the reactor by incoming oil, which immediately vaporizes upon contact with the hot catalyst and after reaction is complete, it is lifted into the regeneration

zone. Catalytic crackers using powdered catalyst in this way are known as FLUIDIZED CATALYTIC CRACKING UNITS.

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FEED: VGO and VR from FPU. The feed is characterized by following:

1) CARBON RESIDUE: Carbon residue of the feedstock is determined by CCR and it indicates the coke-forming tendency of feed. Values for good cracking feedstock are 0.2% wt or less. 2) METAL CONTENT: Most crude oils contain metallic compounds which can enter the catalytic cracker either by entrainment or because the compounds are themselves volatile and actually distilled in the feed preparation units. Ni, Fe, Cu are particularly harmful. Cleanliness of a charge stock with respect to metals is judged by its metal factor, which is defined as: FM = Fe +V +10(Ni+Cu) where, Fe ,V , Ni and Cu are the concentrations of these metals in ppm in the feedstock. FM below 1.0 represents acceptable feedstock. 3) SULPHUR: It is undesirable in catalytic cracker charge as it is in the feed to any refining unit since it causes corrosion of the equipment. Also it increases difficulty of treating products and lower lead response of catalytic cracker gasoline.

CATALYTIC CRACKING REACTIONS:

C2H4 C6H6 Gas oil feed = Iso-octane branched paraffin (30 - 50 C atoms) Cetane Coke(60 % aromatics) Catalytic cracking reactions produce unsaturated short chains like ethylene, excellent high-octane components like benzene and iso-octane and lower molecular weight gas oils like cetane. During cracking, apart from basic reaction of breaking of big molecules to small ones, other reactions like isomerization, cyclization, alkylation, polymerization etc also take place.

CRACKING CATALYST: The catalyst used in catalytic cracking process is a fine

powder made up primarily of Alumina and Silica. Basically there are two types of catalyst -amorphous and zeolite. Zeolite catalyst contains molecular sieves and varying quantities of rare earths. These are formed through reaction of reactive forms of Alumina and Silica.

PRODUCTS: The FCC unit catalytically cracks the vacuum gas oil (VGO) from vacuum
distillation unit (VDU) and feed preparation unit (FPU) to various high priced hydrocarbons. These hydrocarbon vapors are separated into the following products in the fractionating and gas concentration sectiona) Fuel Gas b) LPG c) Gasoline of high octane number d) HSD components e) LDO components f) Fuel oil components Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 49

PROCESS: FCC consists of three sections:

1) Catalyst section 2) Fractionating section 3) Gas concentration section Catalytic section consists of the Reactor and the Regenerator. Feed to the Reactor is obtained by the vacuum distillation of atmospheric residues in FPU. Hot feed from FPU and balanced cold feed from the storage tank is collected in a Raw Oil charge drum. The raw oil from the surge drum passes through a series of heat exchangers where it gets heated against hot products i.e. heavy naphtha, LCO, HCO, CLO and slurry. The temperature of the feed is raised to around 300- 315 deg C. The combined feed enters the reactor riser at the bottom. The hot regenerated catalyst at 600 deg C from regenerator vaporizes the feed, raises it to reaction temperature and supplies the necessary heat of cracking. REACTOR: The reactor riser is a vertical pipe in which all the cracking reactions take place. Hot catalyst enters the cold wall wye section at the bottom of the riser, and meets the raw oil and riser steam. The flow of catalyst is controlled to maintain the desired reaction temperature. The raw oil and the riser steam are premixed in a feed distributor to form an emulsion. The raw oil /riser steam emulsion vaporizes upon contacting the hot regenerated catalyst, accelerating the catalyst and hydrocarbon vapors up the riser. Cracking reactions are carried essentially to completion in the riser with a minimum of over cracking and coke formation. Catalyst and oil contact time using this system is approximately 3 seconds. Catalyst and hydrocarbon vapors exit the riser into the reactor through the down turned disengaging arm. The disengaging arm provides the quick method of separating the catalyst and hydrocarbon vapors. Catalyst falling from the disengaging arm combines with the catalyst recovered from the reactor cyclones to enter the reactor stripping section. Reactor is a cylindrical vessel with a conical bottom. It provides disengaging space for the separation of catalyst from the oil vapor. Catalyst after disengaging from oil vapors falls down and enters the stripper. Oil vapor along with the catalyst particle travels up and enters two single stage cyclones provided at the top of reactor. Entrained catalyst is separated in Cyclones and returned to reactor bed through cyclone dip legs. Flapper valves are provided at the end of dip legs to avoid entry of vapors through dip legs. Vapors from top of both the cyclones leave the reactor separately and join vapor line, which carries vapors to the fractionator. Catalyst disengaging from the down turned arm disengager and reactor cyclones dip legs passes into the catalyst stripper, which surrounds the upper portion of the riser, where it flows over stripping grids, counter current to riser steam .The stripping steam displaces the oil vapor from the catalyst particle and returns the vapor to the reactor for separation in the cyclones.

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REGENERATOR: Coke is deposited on the circulating catalyst in the reaction zone. Spent catalyst flows from the reactor to the regenerator through the spent catalyst slide valve (SCSV). The pressure difference across SCSV is around 0.4 kg/cm2. In the regenerator coke is burnt off with controlled combustion air. Air from air blower is sent to a direct fired air heater where it is heated to around 230 deg. C by fuel gas combustion. This air burns off the coke to CO2 and CO. The heat of combustion raises the catalyst temperature to 640 - 660 deg. C range. This hot catalyst supplies heat to the reactor. The catalyst is recirculated to the reactor through a regenerated catalyst slide valve (RCSV). The pressure drop across RCSV is 0.3 kg/cm2. The regenerator also houses 3 sets of 2 stage cyclones, which separates any entrained catalyst particle from the overhead flue gas. ORIFICE CHAMBER: The purpose of orifice chamber is to reduce the pressure drop across the flue gas slide valve. The high-pressure drop across the slide valve would cause excessive noise and erosion problems. Orifice chamber helps to reduce these problems and brings down the flue gas pressure from 3.4 to 0.3 kg/cm2, which is just sufficient for CO boiler. The gases CO and CO2 come out of 3 sets of stage cyclones in regenerator and leaves from the top. The gases pass through the orifice chamber where a series of restriction orifices reduces the gas pressure. A two-port slide valve (TPSV) installed at the bottom of the orifice chamber diverts the flue gas either to CO boiler or to stack. CO BOILER: The CO boiler is just like any other conventional water tube boiler consisting of two drums and one superheater disposed at the flue gas path. It is a front wall fired, medium pressure (MP) & temperature, natural circulation boiler. The upper drum, which is called steam drum but essentially contains steam and water both, is fed with hot feed water (130-140C) supplied through a feed control valve. The colder water form the upper drum flows to lower water drum through a bunch of tubes called Down Comers which are disposed at the lower temperature zone of the furnace. The water contained in the furnace wall tubes or riser tubes is heated by the heat released in the furnace on combustion of fuel. The heated water in the riser tubes becomes lighter and moves up into the upper drum. These riser tubes are disposed in such a fashion that it makes a closed envelope of the furnace covering all the six sides of the furnace so as to pick-up maximum possible heat. In this way the water circulates from the upper drum to the lower drum through the down comers and from the lower drum to the upper drum through the water wall or riser tubes. This circulation in a boiler is called of natural circulation, which is based upon the principal of Thermosyphon.

The furnace where the combustion of fuel takes place is an integral part of the boiler. The boiler tubes are used to make the enclosure for the furnace followed by insulation and outer sheeting. The space between the tubes is closed with the help of metallic strips, which are welded to the tubes. Hence entire furnace is of welded construction. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 51

FCC FLOW DIAGRAM

Product Typical Yields
Flue Gas

2.5 Kg/Cm2 Catalyst seperation 680 0 C Regenerator

650 0C

DG = 3.0% LPG = 11.0 Gasoline = 25% H.Nap =11% TCO = 33% CLO = 13% Coke = 4%

Catalyst Seperation 4900C 2Kg/Cm2 Density = 80 Kg/Cm2 Ug = 0.1 - 0.3 m/s Stripping Steam

3-5 Sec.

Air 1000 T/hr

Safety Theme; Construction Safety Oil Feed 3500C170

T/hr

FURTHER PROCESSING OF PRODUCTS: The main products from FCC unit are
gasoline and LPG. After these products are separated through fractionation and stabilization section, they are given some chemical treatment like caustic wash and water wash to remove the impurities still present. Following chemicals are used in FCC/GCU:

1.

Caustic Soda.

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2. 3. 4.

Tri-Sodium Phosphate Hydrazine Ahuralan

1) CAUSTIC SODA: Caustic soda is used for LPG and gasoline caustic wash. It removes H2S and lighter mercaptans from these streams. Caustic with approximately 40-45 % strength is received from LPG station through a 2 line into tank. This caustic is diluted to (10-15 %) by adding water to tank. 2) TRI SODIUM PHOSPHATE (TSP): Tri-Sodium phosphate is added to MP steam generators. It helps in reducing scale formation in the steam generators by forming sludge with the scale forming salts. This sludge goes out of the system during blow down operations. Solid TSP is received in gunny bags. Required quantity of TSP is added to chemical mixing tanks and solution is prepared by adding DM water and mixing with the help of motor driven mixer provided on the tank. The normal strength of the solution is 5%. 3) HYDRAZINE (N2H4): While major portion of dissolved oxygen is removed from boiler feed water in deaerator, residual oxygen in boiler feed water is scavenged with the help of hydrazine. N2H4 + O2 2H2O + N2 23 % solution of hydrazine is received in drums/jerry cans of 50 kg. Hydrazine solution of 5 % strength is prepared in chemical mixing tank by adding DM water. The tank is provided with a motor driven mixer. 4) AHURALAN: It is an organic chemical, which acts as a corrosion inhibitor by forming a continuously renewable monomolecular layer on the metal surface with corrosive elements, present in the system.

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GUJARAT HYDRO-CRACKER UNIT (GHC)

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HYDROGEN UNIT
INTRODUCTION: Gujarat Hydrogen plant with a capacity of 38000 tonnes per annum and producing 99.99% pure hydrogen has come up as a part of Gujarat Hydrocracker Project. Hydrogen is generated in this unit by steam reforming of naphtha employing M/s LINDES technology. Hydrogen generated in the plant is consumed in Hydrocracker unit for various chemical reactions. These reactions need very high purity hydrogen to maintain requisite partial pressure of hydrogen in the Hydrocracker reactor. The fall purity results in the lowering of the hydrogen partial pressure, which adversely affects the quality of products from Hydro cracker unit.

FEED: Naphtha PRODUCT: Hydrogen (99.99% pure) PROCESS:

Naphtha Storage and Evaporation Liquid naphtha is supplied to battery limit and is routed from this location into the naphtha butter drum VV 0703. The liquid level in this drum is maintained constant by a level controller adjusting the control valve in the supply line. The naphtha buffer drum is under nitrogen atmosphere, which is due to a continueous nitrogen purge stream to the flare system. The naphtha pump PA 0701 or B takes suction from VV 0703 and supplies the naphtha to the feed system at a pressure of 30 kg/cm2g. The minimum pump flow is controlled by a flow controller, which will discharge back into VV 0703. The amount of naphtha necessary for the process feed is routed via naphtha preheater EE 0709 to the evaporator EE 0706. The level in EE 0706 is maintained constant by a level controller. Too high a level in EE 0706 will stop PA 0701. The evaporation of naphtha takes place in EE 0706 using the heat of the converted gas. The naphtha gas leaving the evaporator is flow controlled,. The control valve upstream pressure is maintained constant by an existing pressure controller which can adjust the converted gas flow rate to EE 0706 and consequently adapt the heat supply to the heat requirement,. Downstream of the flow controller hydrogen is mixed the naphtha gas in order to satisfy the downstream requirements,. Afterwards the hydrogen end naphtha gas mixture bases through naphtha separator VV52 and this is superheated in EE 0707 to an outlet temperature of 3900C. This is also inlet temperature of the desulphurization reactors RB 0701/RB 0702 A/B, which are located downstream of EE 0707. Naphtha used as a fuel for the reformer furnace is supplied from the naphtha fuel pump PA 0702 A or B

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 The amount of liquid naphtha necessary for the furnace firing is flow-controlled before being directly routed to the nozzle of the burners,. The minimum pump flow is controlled by a pressure controller, which will discharge back into VV 0703. Desulphurization Gaseous naphtha leaving the feed superheater EE 0707 at a temperature of 3900C enters the hydrogenation reactor RB 0701 before being routed to the desulphurization reactors. The hydrogenation reactor bed contains CoMo catalyst, where the non-reactive sulphur compounds are hydrogenated to H2S . The desulphurization reactors RB 0702 A/B operate in series. The second reactor can be considered as a safeguard,, which should normally not come into contact with sulphur. Both reactors are identical, the existing line arrangement allows a change in the operating sequence. This change in sequence should be envisaged when a reactor is filled with new catalyst. The desulphurized feedstock leaves the reactor vessel without a notable change in temperature.
Before entering the feed superheater EE 0701, the process steam necessary for the reaction in the reformer tubes is added to the naphtha/H2 gas steam. The amount of steam to be added is controlled by a ratio flow controller with a preset steam-to-carbon ratio.

In the superheater EE 0701 the temperature is increased to 5000C at the outlet of the exchanger. The temperature is maintained by a TIC which actuates a three way valve so that the feed gas can partially be routed through the process steam boiler VV 0701 for an intermediate cooling. The preheated mixture of feed and steam is distributed evenly over the 225 reformer tubes. Steam Reforming: The hot reformed gas leaves the tubes at approx. 8600C is sent via the header and the transfer line to the process gas cooler EE 0705, where it is cooled down to approx 3500C against steam generation. By means of an internal by-pass the exit temperature of the process gas will be controlled for the downstream CO shift conversion. The reformer furnace is fired by the following fuels: Liquid naphtha. Purge gas from the PSA unit. Syngas in case of a PSA shut-down The burners are designed for handling the different gases and are equipped with a separate lance for burning of liquid naphtha. MP steam is used for atomizing of the liquid naphtha. The combustion air is supplied by the blower KA 0702 and enters the burners preheated to 4000C in the preheaters EE 0703 B and EE 0703A. A vacuum of about 20mm WC is maintained in the furnace fire box by a pressure controller, whose control valve is installed at the inlet side of the flue gas fan KA 0701. This machine takes suction from waste heat recovery system and supplies the flue gas at a temperature of about 1630C via the stack YY 0701 to the atmosphere. CO Shift Conversion The reformed gas passes through the high-temperature CO shift converter RB 0703, where most of the carbon monoxide is reacted with the excess steam present in Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 56

The gas stream to produce additional hydrogen and carbon dioxide. CO + H2O CO2 + H2 The reaction is exothermic, and the converted gas leaves the reactor at approx 4270C.

Recovery of Waste Heat Syngas Cooling The heat of the process gas downstream of the process gas cooler EE 0705 is recovered in the following exchangers: Naphtha superheater EE 0707 Naphtha evaporator EE 0706 Economizers EE 0708 A and EE 0708 B Naphtha preheater EE 0709 Demin water heater EE 07010.

From here process gas is fed into the first condensate knock-out drum VV 0704, the condensate is separated and sent to deaerator. The process gas is then cooled in the air cooler EE 0711 and finally in water cooler EE 0712 to approx 380C 1111 and is sent to the PSA UNIT. The process condensate downstream of air cooler and water cooler is separated in the knock-out drums VV 0705 and VV 0706 and sent along with the demin water via preheater EE 07101 to deaerator VV 0709.

Flue Gas Heat Recovery The heat contained in the flue gas when leaving the radiant section of the reformer at about 9610C is used in the Waste Heat Recovery system (WHR). The WHR consists of reformer food superheaters EE 0701, steam superheater EE 0702, combustion air preheater EE 0703 A, steam generation EE 0704 and, finally preheater for combustion air EE 0703 B. The flue gas enters the flue gas fan with approx 1600C. The steam generated in EE 0704 and EE 0705, which can not be used as process steam, will be exported as HP steam and/or pressure and temperature controlled as MP Steam. The reformer flue gas is withdrawn from the WHR by the flue gas fan KA 0701 and routed to the stack YY 0701 before being released to the atmosphere.

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Pressure-Swing Adsorption Unit In the PSA system the hydrogen is separated from the impurities,. Ie CO. CO2 and unreacted CH4. The PSA system consists of 10 adsorber, filled with activated alumina, activated carbon and molecular sieves, At hydrogen product pressure the inputirites are adsorbed by the adsorbers. The regeneration takes place alternatively by depressurization to low pressure and purging with pure hydrogen. During normal operation two of ten adsorbers are in adsorption. Each adsorbers of the ten-bed system is operating in the following steps: Adsorption depressurization, purging pressurization. During the adsorption phase the raw gas flows through an adsorber in upwards direction and the impurities are selectively adsorbed by means of the following adsorbent: water by activated alumina carbon dioxide by activated carbon carbon monoxide and methane by molecular sieve The purified product gas leaves the adsorber and is routed via the product line to BL for export. When the adsorption capacity of one adsorber is saturated, it will be substituted by a regenerated one. Depressurization to regeneration pressure via several pressure steps, thus using the expanded gas to pressurize another already regenerated adsorber, to purge a second adsorber, to pressurize at a low-pressure level a third adsorb to a certain intermediate pressure level and finally to expand to the lowest pressure level into the purge gas line. Purging of the depressurized adsorber with expansion gas of other adsorbers at this low pressure level. Pressurization by means of expansion gas of the other adsorbers and to the final operating pressure by means of hydrogen product. At any given time of the cycle, two adsorbers of the ten-bed system are on adsorption while the other eight are in various stages of regeneration. The advantage of a ten-adsorber unit is the high degree of efficiency and also the possibility of 9-/8-/7-/5-adsorber operation mode which allows also a continous hydrogen production during shut down of one or more adsorbers. The purge gas from the PSA unit contains the impurities CO2, CO, CH 4 and some H2. The purge gas is fed to the buffer vessels VV 0708 A/B , which are designed for a certain hold-up-time to minimize purge gas alteration in concentration, heating value and Wobbe index. The purge gas is returned to the reformer and used as fuel.

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Boiler Feed Water and Steam System Demineralized water from BL is warmed up in demin water heater EE 0710 and sent to deaerator VV 0709. The process condensate from knock-out drums VV 0704 to W 0706 are also fed into the deaerator to reduce the consumption of make-up water. After degasification with steam from battery limit and flush steam from blow-down drum VV 0710, the BFW is treated with hydrazine and morpholine and pumped by boiler feed water pump PA 0703 A + B to the required pressure. Then the BFW is preheated in economizers EE 070 A /B before being supplied to the steam drum VV0701 Trisodium phosphate solution is injected by PA 709 A or B at the inlet to steam drum VV 0701. The process steam is added to the reformer feedstock upsteam the feed superheater EE 0701, the expert steam is sent to BL. A continueous boiler blow-down is provided to maintain the BFW quality in the boiler system. The actual amount of blow-down may be adjusted depending on the water quality. The blow down is flushed into W 0710 and sent to the blow-down drum W 0702, where the blow-down is directly cooled with cooling water and then released to the storm water sewer. The flushing steam is used in the deaerator as stripping steam. Relief System All inflammable gasses are collected in a common flare header and sent to the flare knock-out drum before being routed to the flare stack BL. The knock-out drum is designed so that any condensate entering the drum can be collected. At a certain level height a high-level alarm appears in the control room and draining of the liquid has top be carried out manually. Naphtha is sent to the closed blow-down drum VV 0712, water to the oily sewer. In order to avoid air ingress into the flare system a continuous nitrogen purge from the end of the flare header to the stack is required. Naphtha collected in the buried blow-down drum is sent to BL by PA 0706.

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HYDROCRACKER UNIT
INTRODUCTION: Residue up gradation into middle distillates and light distillates is
currently being done in the Indian Refineries primarily by employing FCC process, delayed coking process & visbreaking. Visbreaking is adopted primarily to reduce the viscosity of the residue thereby making it marketable. Delayed coking is adopted if coke is also to be a product. The quality of products obtained from FCC, delayed Coker & Visbreaker are relatively poor in quality with respect to stability, & sulphur and have to be blended with other straight run products to be able to market them. Otherwise, product treatment would be necessary (Hydro-treatment, Merox treatment etc.). In view of these problems Hydro cracking process is gaining more and more popularity for upgrading residues into higher value products Hydrocracking is an extremely versatile catalytic process in which feedstock ranging from Naphtha to Vacuum Residue can be processed in presence of Hydrogen and catalyst to produce almost any desired products lighter than the feed. Thus if the feed is Naphtha, it can be converted into LPG and if feed is Vacuum Gas Oil as in our Refinery, it can produce LPG, Naphtha, ATF, Diesel in varying proportions as per design requirement. Primary function of Hydrocracker unit is to maximize middle distillate production in Gujarat Refinery. The Hydrocracker is made-up of three major sections: the make-up hydrogen compression section, the reactor section (two stage) and the distillation section. Reactor Section: The feedstock is combined with hydrogen at high temperatures & pressures and is catalytically converted to lighter transportation fuels. The reactor section is composed of the first stage reactor and the second stage reactor. Make-up Hydrogen Compression Section: It provides hydrogen to each reactor section; the reaction products are separated and cooled. Distillation Section: It consists of the atmospheric fractionation, light ends recovery, LPG treating and a vacuum column. Hydrocracker Unit operates under two different catalyst conditions viz. Start of Run (SOR) & End of Run (EOR). When the catalyst is new or freshly regenerated, it is SOR condition. The catalyst gets deactivated due to coke deposition (about 12-18 months) and requires regeneration to operate under design stipulations. The operating condition just before regeneration is called EOR operation.

FEED: Feed consists of VGO from FPU PRODUCTS: The primary products from HCU are:
L.P.G Stabilized Light Naphtha Heavy Naphtha Aviation Turbine Fuel (ATF)/ Superior Kerosene (SK) High Speed Diesel (HSD) Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 60

PROCESS:
In Hydrocracker, the VGO feed is subjected to cracking in 2 stage reactors over catalyst beds in presence of Hydrogen at pressure of 170 kg/cm2 & temperature raging from 365 to 441 deg. C. The cracked products are separated in fractionator. Light ends are recovered/stabilized in debutanizer column. The process removes almost all sulfur and Nitrogen from feed by converting them into H 2S & Ammonia respectively. Thus the products obtained are free of sulfur & nitrogen compounds and are saturated. Therefore, except for mild caustic wash for LPG, post treatment is not required for other products. The overall flow scheme of the unit is indicated in the drawing No. RF 880110. The unit consists of the following sections: (i) First stage Reactor section (ii) Second stage Reactor section (iii) Fractionation Section (iv) Light Ends Recovery section FIRST STAGE REACTOR SECTION

Vacuum Gas oil feed is supplied from FPU and heated in exchangers and brought to the pressure of 185 Kg/sq.cm by feed booster pumps. It is mixed with recycle Hydrogen and pure Hydrogen from make-up compressors and further heated in reactor effluent exchanger followed by furnace upto 385 Deg. C before it enters the First Stage Reactor. The first stage reactor contains three catalyst beds with two intermediate quench zones which use recycle gas as quenching medium. The reactor effluent is cooled in exchangers, steam generators and finally in an air fin cooler upto 65 deg. C. It is flashed in the High Pressure Separator (HPS) from which Hydrogen Rich gas is recycled back to the reactor. The liquid product from the separator flows through a Power Recovery Turbine (PRT) to the Cold Low Pressure Separator (CLPS). The first stage reactor converts approximately 40% of the
feed to middle distillates and lighter products. SECOND STAGE REACTOR SECTION

Converted feed from the first stage reactor is removed in the fractionator section and unconverted material from the first stage forms the feed to the second stage. Feed from vacuum column bottom is boosted upto 185 kg/cm2 and mixed with recycle gas and pure hydrogen from make up compressors and is heated in the reactor effluent exchanger followed by 2nd stage reactor furnace upto 345 Deg. C before it is sent to the reactor. This reactor also contains three catalyst beds with two intermediate quench zones which use recycle gas as quenching medium. The reactor effluent is cooled in the exchangers, steam generators upto 204 deg. C and is fed to Hot High Pressure Separator (HHPS) Liquid from HHPS flows through a power recovery turbine, which drives the feed pump, and goes to Hot low pressure separator (HLPS) before going to fractionation section. The hydrogen rich gases are cooled in exchangers followed by air cooler upto 65 deg. C before entering into Cold High Pressure Separator (CHPS).

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FRACTIONATION SECTION

Li uid from HLPS is heated in the exchangers and finally in a furnace upto 345 Deg. C before it is sent to fractionator column. The overhead products are off-gases and light naphtha. Off gases are washed with Amine to remove H2S and are sent to the Fuel Gas System. Heavy Naphtha is withdrawn at 146 Deg. C as first draw off. It is stripped in a stripper and cooled before it is sent to storage. The second draw off is ATF at 188 Deg. C. It is stripped and then cooled in feed exchanger, steam generators followed by coolers before it is sent to storage. The third draw off is HSD at 286 Deg. C. It is also stripped in a steam stripper, cooled in steam generator and water cooler before it is sent to storage. The bottom of the fractionator is pumped to Vacuum Column. The bottom temperature of the column is maintained at 377 Deg. C using a reboiler furnace. HSD is withdrawn as a side cut of vacuum column and blended with diesel from fractionator after cooling in exchanger and cooler. The bottom of the vacuum column is feed for second stage reactor.
LIGHT ENDS RECOVERY SECTION

Light Naphtha from the fractionator is sent to deethaniser, where gases are removed and sent to Amine Absorber where the H2S is absorbed in the Amine and H2s free fuel gas is sent to Fuel Gas system. Rich amine with dissolved H2S is sent to Amine Regeneration Unit in Sulfur Recovery Unit Block. The bottom of deethaniser is sent to debutaniser, for the recovery of LPG. LPG is taken out from the top and sent to treating section where it is washed with caustic for removal of H2S. The stabilised Naphtha from the bottom of the stabilizer is sent to Hydrogen Unit for production of Hydrogen. DEETHANISER
Light naphtha from Atm. Fractionator overhead section is pre-heated to 59 Deg. C. in Exchanger EE-021 by naphtha stabiliser bottom product before entering deethaniser column. The feed temperature is monitored by TI-8003. The deethaniser column is provided with 34 valves trays. The feed enters above Tray-24. Deethaniser removes gases lighter than ethane, H2S & water from Unstabilised naphtha. The pressure of the deethaniser and the balance of the fuel gas treating section is controlled by PIC-8001 on deethaniser overhead which regulates the sweetened fuel gas flow to F.G. System. Cool Light naphtha (Sponge oil) is combined with deethaniser overhead vapor to maintain good LPG recovery. The combined stream is partially condensed in water cooler EE-022 and collected in reflux drum VV-013. The reflux drum temperature is maintained at 38 Deg. C by TIC 8101 on outlet of cooler which controls the flow of cooling water in the cooler. The vapours from reflux drum is sent to fuel gas treating section. Separated water is sent to sour water stripper under interface level control (LIC 8102). Provision is also made to close the Sour water outlet valve LV-8102 through a solenoid valve SOV-8102 on actuation of low level switch LSL 8102 with low interface level. Total hydrocarbon from the reflux drum is pumped back to deethaniser column under reflux drum level controller LIC-8101. The flow is measured by FI-810B. The deethaniser overhead temperature is monitored by TI-8002. The vacuum column pump around supplies heat to the deethaniser reboiler EE-023. The reboiler is a vertical exchanger located adjacent to the column. The reboiler heat input is varied to hold a constant temp. of 134 Deg. C at Tray 2 of the column. This temp. is controlled by TIC-8001

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which resets the flow controller FIC-8001 which regulates the vacuum pump around flow through reboiler, balance being by passed through reverse acting double control valves FV-8001 A & B. A water draw off tray (Tray-30) & water draw off Pot VV-015 are provided to remove any water which may condense during startup or upset conditions. Condensed water is mixed with cooled deethaniser overhead stream D/S of cooler EE-022. Deethaniser bottoms is pumped to naphtha stabiliser CC-008. The bottoms flow rate is controlled by FIC-8002 which is reset by deethaniser level controller LIC-8001. NAPHTHA STABILISER Stabiliser column separates the LPG from light naphtha. Stabiliser column is provided with 44 valve trays for fractionation. Unstabilised naphtha at 130 Deg. C enters the column above Tray 27. The overhead vapours from stabiliser column is totally condensed in air cooler EA-008. The temperature at the outlet of aircooler is controlled at 67 Deg. C by TIC-8308 which regulates the speed of fans of air cooler. The stabiliser overhead pressure is maintained at 12.3 Kg/cm2g through split range controller PIC 8301. The controller bypasses part of hot vapours from stabiliser overhead directly to reflux drum VV-016 through PV-8301B in case the pressure is increasing. Otherwise, the control valve PV-8301 A which is located at the outlet of air cooler EA-008 will regulate the flow to maintain the set pressure. The sour gas from the reflux drum is sent to the inter stage K.O. drum feed D/S of cooler EE-019 by pressure controller PIC-8302 which regulates the flow of sour gas ex reflux drum to maintain drum pressure at 12.0 kg/cm2g.Provision to route the sour gas to flare via PIC 8302 also exists. Condensed LPG is pumped by PA-016A/B and divided in two streams. One stream under flow control (FIC-8301) is sent back as reflux to the top of the column to maintain overhead temperature of 76 Deg. C which is monitored by TI-8301. The other stream is the product LPG which is sent to LPG treating system under reflux drum level controller LIC-8302. Provision of low level alarm is also made in the reflux drum. The vacuum column pump around supplies heat to the stabiliser reboiler EE-025. The reboiler heat input is varied to hold a constant temp. at Tray-2 of the column. This temp. is controlled by TIC-8303 which resets the flow controller FIC-8303 which regulates the flow of vacuum pump around through the reboiler by reverse acting double control valves FV-8303 A & B. The reboiler inlet and outlet temperature on stabiliser bottom liquid is monitored by TI-8314 & TI8315 respectively. The stabiliser bottom which is light naphtha, under flow controller FIC 7911 is cooled from 162 Deg. C to 149 Deg. C in Exchanger EE-021 thereby heating up the deethaniser feed. Light naphtha is further cooled to 65 Deg. C by air cooler EA-009. Inlet and Outlet temperatures of air cooler are monitored by TI-7904 and TI-7905. Part of light naphtha called sponge oil after air cooler is pumped by PA-17 A/B and sent to deethaniser overhead vapour line upstream of water cooler EE-00-22 to improve LPG recovery as stated earlier. The flow of sponge oil is controller by FIC-7901. The remaining part of light naphtha is cooled in water cooler EE-026 to 40 Deg. C, monitored by TI-7906. It is then sent to storage under stabiliser bottom level controller LIC-8301. The flow of light naphtha to storage is indicated and totalised by FQI-7902. Additionally one shut off valve LSV-8301 is provided in light naphtha line going to storage upstream of LV 8301. In case of very low level of stabiliser, switch LSLL 8301 actuates and through solenoid valve shuts off LSV 8301.

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LPG TREATING SYSTEM LPG treating section removes traces of H2S and free water to meet LPG specification. LPG from stabiliser reflux drum is water cooled from 67 Deg. C to 40 Deg. C in EE-024. Temperature is monitored by TI-8310. Provision of routing part of LPG ex EE-024 as reflux to CC-08 also exists. Facility of LPG leak detection and one thermal relief valve TSV-8301 is provided in the cooling water outlet line. The cooled LPG then combines with caustic pump around stream. The combined stream then flows through a static mixer (JX-003) and a mixing valve (HV 8401) to ensure good contacting between the phases. The aqueous phase is separated from hydrocarbon phase in caustic washer VV-017. PDI-8406 measures pressure drop across the jet mixer or total jet mixer and mixing valve. Caustic pump around is maintained by PA-19 A/B and flow is monitored by FI-8402. Periodically, once every two weeks ( period may change depending upon the H2S content and circulating caustic strength), spent caustic is withdrawn from caustic washer and sent to caustic degasser VV-020. Make up caustic is then pumped to VV-017 by PA-018 through a pulsation damper. Flow of makeup caustic measured by FI-8401. Only half of caustic hold up is replaced at a time. Level gauge with high & low level alarms are provided in VV-017. Caustic is heated by LP steam in degasser vessel VV-020. Gases from VV-020 are sent to flare system. Spent caustic is pumped from degasser to effluent treatment system at a low flow rate to avoid upsetting effluent treater. Level gauge with high & low level alarms are provided in degasser VV-020. Caustic washed LPG flows to water washer VV-018 to remove caustic traces. Water is pumped to VV-018 by pumps PA-020 A/B. Water washed LPG flows out from VV-018 through a demister Pad which removes the entrained water and then goes to LPG coalescer VV-019 to remove free water. LPG flows through coalescer pad. Separated LPG from top is then sent to the storage. Flow of LPG with totaliser is monitored by FQI 8505. PDI-8501 measures the pressure drop across the coalescer pad. Water from VV-18 flows under interface level control (LIC 8501) to water degasser. Water from coalescer also combines with water from VV-018. Water from degasser VV-021 is pumped by PA-030 to sour water stripper. Pump is having auto start & stop facility with high & low level in degasser. SOUR GAS TREATING SECTION Sour gas from deethaniser reflux drum, atm fractionator overhead from VV-012 and vapour from CLPS are treated here to remove H2S. These streams are combined and passed through filter separator GN-002 to remove entrained liquid & solid particles and then to KOD 06VV051. Hydrocarbon liq. or solids can cause foaming in the absorber. Provision to send the separated liquid from GN-002 back to deethaniser reflux drum VV-013 also exists. Level gauges with high level alarms are provided in filter separator. PDI-8201 measures pressure drops across filter separator. Filter by pass is also provided which is normally kept closed. VV051 liquid is normally drained to flare KOD. Sour gases from filter separator and VV051 is sent to H2S absorber CC-007. Temperature of feed gases to absorber is monitored by TI-8203. Feed gas temperature is kept at about 40 Deg. C. H2S absorber is a packed tower which uses lean Diethyl Amine (DEA) to remove H2S from the gas streams. To avoid condensing hydrocarbons in absorber, lean DEA temperature is kept at least 6 Deg. C greater than hydrocarbon temp. The rich DEA leaves the H2S absorber under level control (LIC 8203) and is sent to SRU block to regenerate the DEA solution. The rich DEA

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contains 0.25 moles H2S per mole of DEA. Flow of rich DEA is monitored by FI-8202B and temperature by TI-8201. Oil collected in the oil skim tray is periodically removed. PDI 8202B indicates pressure drop across the packing in the tower. The sweet gases from absorber top are sent to a knock out drum VV-014 to remove entrained DEA solution. Collected DEA solution from VV-014 bottom is sent along with rich DEA. Level gauge with high level alarm is provided in the knock-out drum. Sweetened gas is then finally sent to fuel gas system under pressure controller PIC-8001 which maintains the set pressure (13.4 Kg/cm2g) on the overhead line of Deethaniser column. Temperature of fuel gas to F.G. system in monitored by TI-8204. The flow rate is measured by FI-8203. VACUUM FRACTIONATION Fractionator bottom at 334 Deg C is pumped to a vacuum fractionator CC-005 to recover the remaining HSD from the uncovered VGO feed before it is sent to IInd stage reaction section for further conversion. The vacuum column has three packed beds. HSD is drawn from below the top bed. The atmospheric fractionator bottom enter the vacuum column above the bottom bed through a strainer (GN-003A/B). The flow is controlled by FIC-7404 which is reset either by level controller LIC-7402 of the vacuum column bottom or by the level controller of the atmospheric column bottom. Low flow circulation of pump PA-005 A/B, i.e. 2nd stage feed pump joins the vacuum feed D/S of control valve FV-7404. A furnace reboiler FF-004 supplies heat for fractionation. The reboiler furnace outlet temperature is maintained at 376 Deg C by TIC-7410 which controls the firing in the furnace. The reboiler feed is pumped by PA-051 A/B. HSD is the stream condensed in the top packed bed by the cool pump around stream entering the column above the top packed bed at 89 Deg C. All of the liquid from the top packed bed at 89 Deg C. All of the liquid from the top bed is withdrawn via a total draw of Tray at 217 Deg C. Some of this Liquid is returned to the column above the middle packed bed. The liquid rate returned back to column is controlled by FIC-7403 which is reset by LIC-7401 which is level controller of the liquid draw off tray. The remaining liquid which is vacuum column pump around supplies heat to naphtha stabiliser reboiler EE-025, deethaniser reboiler EE-023 and cold feed (VGO) from tankages in EE-030 (if required). The pump around is then cooled from 112 Deg C to 89 Deg C in air cooler EA-007. Some of the cooled liquid is withdrawn as HSD product. HSD product flow rate is controlled by FIC-7402. The rest of the cool pump around flows to the top of the top packed bed under flow control set by FIC-7401. All the feed streams to the column are sent through strainers to remove the corrosion products which otherwise would plug liquid distributor nozzles or packings. Vapours which are not condensed in top bed are sent to the overhead vacuum system. Vacuum is maintained in the column by a single stage ejector JA-003 A/B. MP steam under pressure control at U/S of ejector by PIC-7611 is supplied to ejectors. Overhead vapour is water cooled in the precondenser EE-027 before going to the ejector and water cooled in the after condenser EE-028 after going through the ejector. All vapour, liquid Hydrocarbon & water collect in the seal drum VV-025. The vapor circulates back to ejector and the vapour rate is controlled by PIC-7601, the pressure controller on the vacuum column overhead which maintains the overhead pressure at 190 mm of mercury column. Provision to route the hydrocarbon liquid by the pump-06AP22 (under auto start/stop provision with high & low level in seal drum) to the atmospheric fractionator feed upstream of EE-010 also exists. In case of very low generation, oil is normally

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routed to OWS. Water from the seal drum flows to oily water sewer under interphase level controller. The vacuum column bottom stream is pumped by PA-039 A/B to preheat atmospheric fractionator feed in EE-010A/B before it is sent to 2nd stage reaction section feed pumps PA-005 A/B at 288 Deg C. A low pressure switch PSLL 7401 with alarm is provided which will actuate the auto start of the other pump in case of problem in the running pump. Provision is given to send the vacuum column bottom to off sites/FCC/LSHS via air cooler EA-010 and rundown cooler 06EE051A/B in case the 2nd stage is under shutdown or unit is operating at less than 100% conversion. Normally it is routed to FCC.

CHEMICAL DOSING:

1) DIMETHYL DISULFIDE (DMDS) INJECTION SYSTEM: Sulfiding is required to

stabilize fresh or regenerated catalyst, which in turn promotes a smooth start-up, better activity and lower fouling rate. For sulfiding of catalyst Dimethyl Disulfide (DMDS) is injected in recycle gas, going to reactor. 2) ANTISTATIC ADDITIVE DOSING SYSTEM: Antistatic additive (Stadis-450) is dosed in ATF, which gives it the property to dissipate the build up static electricity during its transportation in pipes. The dosing rate is adjusted to meet the specifications of electrical conductivity of 50 - 450 Ps/m. The dosing is done in the ATF rundown line downstream of the cooler. HYDROCARBON REACTION CHEMISTRY: Hydrocarbons are classified into four major groups according to the types of carbon-to carbon bonds they contain: 1) Aromatics- They contain one or more benzene nuclear unsaturated, six member rings in which some electrons are shared equally by all the carbon atoms in the ring. If some of the rings share two or more carbon atoms, the compounds are referred to a condensed ring, or polycyclic, or polynuclear aromatics. As a group, aromatics have higher carbon- to-carbon ratios than any other group. They have relatively low API gravities and tend to produce smoke when burned so they make poor jet fuel. Aromatics have good antiknock properties and make excellent high-octane gasoline. 2) Naphthenes- They are ring compounds without any benzene nuclei. The rings are typically five or six membered saturated rings. Naphthenes have intermediate API gravities and burning qualities. 3) Paraffins- They are straight chain or branched-chain. Straight paraffins are called normal paraffins and have very high freeze points so they make poor jet fuel. Branched- chain paraffins are called iso-paraffins. They make excellent high smoke, low freeze jet fuel. As a group, paraffins have the highest API gravities. 4) Olefins- They are reactive molecules, which contain one or more double bonds in an otherwise paraffinic structure. Olefins do not occur naturally in crude oil because any olefins would have long since reacted to form other molecules during the age long underground aging process in which crude oil is formed. Olefin can be formed as reaction intermediates during hydrocracking, but the high hydrogenation activity of the catalyst prevents any olefins Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 66

from showing up in reactor products. Hydrocracker feeds also have lesser amounts of molecules, which contain chemically bound sulfur or nitrogen atoms in aromatic or naphthanic structures. The following molecules are typical of the kinds present in hydrocracker feeds and products: Paraffins Naphthenes Aromatics Sulfur Compounds Nitrogen Compounds CATALYST CHEMISTRY: Hydrocracking catalysts are dual functional, which means that they have both acid cracking sites and metal hydrogenation sites. The hydrogenation sites provide olefin intermediates and saturated olefin products. They saturate some of the aromatic rings and prevent the accumulation of coke on the acid sites by hydrogenating coke precursors. The acid sites provide the carbonium ion intermediates and the isomerization activity that result in the dominance of isoparaffin products. More acidic catalysts produce a lighter yield distribution of higher iso-tonormal ratio products. Higher hydrogenation activity catalysts produce more saturated products with a heavier yield distribution. CATALYST SULFIDING: Sulfiding is done to regenerate strong acid sites on catalyst, which were neutralized by nickel salts during catalyst manufacture. An unsulfided catalyst has much lower cracking activity and produces products of low iso-to-normal ratio. Sulfiding itself proceeds as two separate reactions. The cracking of DMDS: CH3-S-S-CH3 + 3H2 = Followed by the sulfiding proper: 2H2S + 3 NiO + H2 = CATALYST REGENERATION: Catalyst Regeneration consists primarily of burning off accumulated coke on the catalyst during the oxidation phase: 4C1H1 + SO2 = 4CO2 + 2H2O 2CH4 + 2H2S Ni3S2 + 3 H2O.

As an unwanted side reaction, some of sulfur (from sulfiding) is also oxidized: Ni3S2 + 4O2 = NiSO4 + 2NiO + SO2, Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 67

to yield nickel sulfate, nickel oxide, and sulfur dioxide. In the reduction phase, the nickel sulfate is eliminated to prevent temperature runaway during subsequent sulfiding: 3NiSO3 + 10H2 = Ni3S2 + SO2 + 10 H2O

Since some of the sulfur is retained as nickel sulfide, the subsequent sulfiding uses less DMDS than used for sulfiding of fresh catalyst. As a side reaction during reduction, metal oxides are converted to metals: NiO + H2 = Ni + H2O

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MOTOR SPIRIT QUALITY UPGRADATION UNIT (MSQU)

INTRODUCTION:The Motor Sprit Up Gradation project has been envisaged to produce 850 TMTPA of MS. The unit will produce both BS-II and Euro-III standard motor Sprit. It has a capacity to produce 450 TMTPA of BS-II standard and 400 TMTPA of Euro III standard MS.The unit consists of a no of processes viz., FCC gasoline Splitter (550 TMTPA), Naphtha hydrotreater (600 TMTPA), Platformer, Continuous catalyst regeneration (600 TMTPA), Reformate splitter (600 TMTPA), Merox (450 TMTPA). The final blending of MS of both the standard will be done in an automatic blending station. The existing facilities of the refinery will be connected with both ISBL and OSBL of MSQ. Brief Description Of The Processes: FCC gasoline (C5-140 cut) is split into three fractions by distillation method in two no of columns, Splitter-1 & Splitter-2. The lighter fractions, light cut and heart cut gasoline are treated in the Merox unit to remove Mercaptans (Sulphur compounds) and then sent to storage for blending in the automatic blending station. The heavy cut gasoline which is the feed to the Continuous Catalytic Reforming unit for boosting of octane no, is fed to the Naphtha hydrotreater unit along with Straight run Naphtha from AU-I and AU-II for removal of impurities like Sulphur, Nitrogen, Metals, Oxygen etc and for saturation of olefins present in it. The impurities in NHTU feed are catalytic poison to the platforming catalyst hence these are removed. The product from Naphtha hydrotreater unit which is now free of impurities is fed to Continuous Catalytic Reforming unit (CCRU) for boosting of octane no. In the, platformer section of CCRU the feed comes in contact with Hydrogen and a catalyst containing Platinum and chloride and undergoes no of reactions viz., Dehydrogenation, dehydrocyclization, Isomerization, cracking followed by coking. The reactions take place in four no rectors stacked one above another. In the reactors a no of undesirable reactions are also taken place. The cokes deposited in the catalyst retards the reactions in the platformer reactors; hence these cokes are removed from the catalyst by burning in the regeneration section of CCRU In CCR platformer, additional facilities are provided to recover hydrogen in PSA (Pressure swing adsorption) hydrogen recovery section, Deethaniser is provided for stabilization of LPG and a separate Recovery plus section (liquid recovery) is provided to increase reformate yield and to increase hydrogen purity. In the regeneration section, the cokes deposited on the catalyst are burned by oxygen and reactivated in a regenerator and sent back to the Reactors. Continuous catalyst circulation facility is there in the regeneration section. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 69

The products of the plat former section is Hydrogen, LPG, Fuel gas and Reformat. The reformat is sent to Reformat splitter unit for further split to produce feed for Udex unit In Reformat splitter unit the reformat is split into two fractions, light reformat and heavy reformat in a single distillation column. The light reformat is sent to Udex unit for Benzene production and the heavy reformat is sent to automatic blending station for MS production. MEROX PROCESS DESCRIPTION : The UOP MEROX process is an efficient and economical catalyst process developed for chemical treatment of petroleum distillate for removal of sulfur present as mercaptans (MEROX EXTRACTION) and conversion of mercaptans sulfur to a less objectionable form (MEROX SWEETENING). The word MEROX is derived from 'MERcaptan OXidation. The principle is based on the ability of a Catalyst composed of iron group metal chelates, to promote the oxidation of Mercaptans to Disulphides at ambient temperature using air as the source of Oxygen. MEROX ADVANTAGES: Relative to other treating processes, the Merox process has the following advantages: Low operating cost and investment requirement: The non-corrosive environment in which the process operates requires no alloys or other special materials, thus minimizing investment; investment in many applications is very low based on the conversion of existing equipment to Merox treating. Utility and chemical requirements are minimal. Ease of Operation: Merox process units are simple to operate; the air injection rate is the only direct adjustment necessary to accommodate wide variations in feed rate or mercaptan content. Operating labour requirements are minimal. Proven reliability: The Merox process has been widely accepted by the petroleum industry; over 1500 units of various kinds (extraction, liquid, and fixed bed sweetening) have been placed in operation. Minimal chemical disposal requirements. Proven ability to produce specification products: There is no damage of product deterioration due to side reactions or addition of undesirable materials to the treated product. Brief Process Description Pre-treatment: Before entering naphtha in Merox sweetening unit passes through extractor, in with small amount of mercaptans are extracted by using counter- current flow with caustic. The naphtha from top of extractor is sent to sweetening part of Merox Unit. The bottom of extractor is sent to Oxidizer for oxidising extracted mercaptans to disulphide. The flow schemes for the Minalk unit are very simple. Air and caustic are injected into the hydrocarbon feed stream from the top of extractor, which then enters the Minalk reactor down flow. Sweetened product, essentially free of entrained caustic, is withdrawn directly from the side of the fixed bed near the bottom of the reactor. The coalesced aqueous phase collects at the bottom of the vessel and is discharged via a small drain pot to sewer or to the spent caustic disposal system. The charcoal bed is an excellent coalescer. The hydrocarbon feed and process air to the Minalk unit enter on flow control and sweetened product leaves on pressure control. The spent caustic leaves the drain pot on level control. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 70

Air is injected into the hydrocarbon stream via an air mixer. This ensures a uniform dissolution of air in the hydrocarbon just before entering the reactor. The air injection line is provided with a cut-off valve, which stops the airflow on low hydrocarbon feed flow rate. An excessive amount of air injection for a given feed rate can cause the formation of a separate air phase at the top of the reactor, which will promote channelling in the catalyst bed. A continuous injection of dilute caustic is required to maintain a minimum level of alkalinity in the reactor. Caustic is injected through an atomising nozzle to ensure uniform dispersion in the feed. MEROX PROCESS: The word MEROX is derived from the 'MERcaptans OXidation'. UOP of USA patents this processes. Mercaptans have the chemical formula R-S-H where R - is the Hydrocarbon group. Example: CH3 - S-H --------Methyl Mercaptant C2H5 - S-H -------Ethyl Mercaptant PRINCIPLE OF MEROX TREATING: The MEROX process is a chemical treatment of petroleum distillates to Remove mercaptans or to convert them into Disulphides. This process is applicable to the treatment of stocks boiling up to 350C. The principle is based on the ability of a Catalyst or Catalysts composed of iron group metal chelates, to promote the oxidation of Mercaptans to Disulphides at ambient temperature using air as the source of Oxygen. RSH + 1/4 02 1/2 RSSR + 1/2 H20 TYPE OF MEROX UNITS: There are two types of Merox Units: 1. Extractive Merox (Removal of Mercaptans) 2. Sweetening Merox (Conversion of Mercaptans) EXTRACTIVE MEROX: Mercaptans of lower molecular weight are soluble in caustic solution. In the extraction unit, sulphur reduction is directly related to the extractable mercaptan content of the fresh charge. The elimination of Mercaptans is obtained by counter current contacting of Hydrocarbons with a strong aqueous alkali solvent. The mercaptant rich solvent, which also contains the dispersed MEROX catalyst, is sent to a regeneration section where air is injected and the mercaptans are oxidized to disulphides. The disulphides are subsequently separated from the solvent by coalescing, gravity settling, and decanting; the regenerated lean solvent is recycled back to the extractor. Thus, the extractive Merox consists of two steps; mercaptan extraction and solvent regeneration. The mercaptant in contact with the caustic solution combines chemically with this solution according to the following reaction. RSH + NaOH RSNa + H20 The spent caustic is then oxidized with air in an oxidizer in the presence of Merox Catalyst, this is readily oxidized to Disulphide and Caustic is regenerated. RS Na + 1/2 02 + 1/2 H20 NaOH + 1/2 RSSR.

The oxidation reaction is irreversible and the amount of Oxygen needed is independent of Mercaptans Molecular weight or structure. The mixture of excess air, Caustic and Disulphides is passed into the Disulphide separator. Here the excess air is vented out, the Disulphide oil is decanted and the caustic recycled back to the extractor. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 71

SWEETENING MEROX: (Minalk sweetening) For the Minalk unit (and for all sweetening type units), the mercaptans are converted directly to disulfides, which remain in the product; there is no reduction in total sulphur content. Because the vapour pressure of disulfides are so low relative to those of mercaptans, their presence is much less objectionable. The Merox Minalk process relies on a small, continuous injection of an appropriate strength alkali solution rather than gross intermittent alkali saturation of the catalyst bed as used in conventional Merox fixed bed sweetening. This continuous, small injection of alkali, such as dilute sodium hydroxide solution (2-5 wppm), is held to a minimum but enough to provide the needed alkalinity. In this way mercaptans are oxidized to disulfides and do not enter into a per oxidation reaction in case of insufficient alkalinity. For Minalk Merox systems, pre-treatment are rarely required. The need for pre-treatment depends on feed characteristics, treated product specifications, and end-use. For charge stocks such a light gasoline, where more than low ppm levels of hydrogen sulphide are present, the charge stock is passed through a guard caustic scrubber to ensure essentially complete removal of H2S. Hydrogen sulphide does not position the catalyst but it competes with mercaptans for the available catalytic sites and available oxygen. Post treatment is not required on Minalk sweetened streams. Sweetening is the conversion of Mercaptans into Disulphides in hydrocarbon stream without any change in the total sulphur content. Sweetening is different from extraction in which the Mercaptan molecules are removed with a resultant reduction in Sulphur content. In sweetening, there is no reduction in sulphur content; only a chemical transformation of Mercaptans into Disulphides takes place. This process is suitable for heavier Hydrocarbons in which the present Mercaptan Sulphur represents a very small quantity of total sulphur. AFTER TREATMENT: In many case such as Gasoline no after treatment is required. Whereas in the case of Aviation Turbine Fuels, to meet the very rigorous 'Thermal stability and water tolerance' tests the treated stream is given a water wash, followed by a sand bed coalescer or salt drier for removing the entrained water. Merox Catalysts Extractive Merox : The Extractive Merox Process requires the use of UOP Merox reagent WS. It is supplied as a dark blue water solution packaged in 3.8 litre sealed polyethylene bottles. Each bottle contains one Kg of water-soluble active ingredient. Catalyst concentration is a direct operating variable in the extractive process. Minalk sweetening Merox: The fixed bed Merox process has the Merox catalyst deposited upon the extended hydrophilic surface of specially selected activated charcoal. The function of the activated charcoal is to provide a vast surface where mercaptans, catalyst, caustic, and oxygen may come into contact for completion of the sweetening reaction. To provide the alkaline medium, the charcoal is kept saturated with caustic solution. The fixed bed process utilizes a type of Merox catalyst that is not dispersible in caustic so as to prevent the caustic from removing the catalyst from the charcoal surface.

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NAPTHA HYDROTREATING UNIT (NHTU)

Introduction to NHT Unit Naphtha Hydrotreater (NHT) is a catalytic refining process employing a select catalyst and a hydrogen rich gas stream to decompose organic sulphur, oxygen and nitrogen compound contained in hydrocarbon fractions. In addition, hydrotreating removes organo-metallic compounds and saturates olefinic compounds. The hydrotreating process is commonly used to remove Platforming catalyst poisons from straight run or cracked Naphtha. The catalyst employed has alumina base impregnated with cobalt or nickel and molybdenum. A relatively high percentage of carbon on the catalyst does not effect its sensitivity or selectively. Volumetric recoveries of product depend on the sulphur and olefinic contents. Organo-metallic compounds, notably arsenic and lead are permanent poisons to Platinum Catalyst. Complete removal of these materials by hydrotreating will give longer ultimate catalyst life in the Platforming unit. Sulphur is a temporary poison to Platforming catalysts but platforming catalyst activity causes an unfavorable change in product distribution and increases coke lay down. Organic nitrogen is also a temporary poison to platforming catalyst, even small concentration of nitrogen in Platformer causes large activity off-set as well as deposit of ammonium chloride salts in the Platforming unit cold sections. The Naphtha Hydrotreating Process makes a major contribution to the ease of operation and economy of Platforming. Much greater flexibility is afforded in choice of allowable charge stocks to the platforming unit. Because this unit protects the platforming catalyst, it is important to maintain consistently good operation in the hydrotreating unit. The hydrotreating process unit in IOC, J project will be used to remove Platforming catalyst poisons from straight run Naphtha. The hydrotreating unit is designed for 600,TMTPA. Brief Process Description Feed Naphtha from the FCC Gasoline splitter unit and from storage is routed to the Feed surge drum (14-VV-HW-001). Any water collected in the feed surge drum, is routed to the OWS (normally there should be no flow). The naphtha is charged to the Reactor section by the Charge pumps (14-PA-CF-001A/B). Reactor section Naphtha from the charge pumps (14-PA-CF-001A/B) is combined with Hydrogen-rich recycle gas from the reactor loop. The naphtha is then preheated in the Combined Feed Exchanger (14-EE-00-001), by effluent from the reactor (14-RB-00-002).The stream is further heated to the required reaction temperature in the charge heater (14-FF-00-001), before flowing to the Reactor (14-RB-00-002). The Reactor removes sulphur, nitrogen and other contaminants from the feed in a downflow catalyst bed. The reactor effluent vapor exchanges heat with the reactor feed in the Combined Feed Exchanger (14-EE-00-001). Cold condensate is then continuously injected by the Wash Water Injection Pump (14-PA-CF002A/B) form the Water Break Tank (14-VV-VW-002), to prevent the deposition of salt. Reactor effluent flows out of the Product Condenser (14-EA- FN-001) at low enough temperature to recover the naphtha and enters the Separator (14- VV-HI-003). A mesh blanket coalescer in the separator ensures separation of the naphtha, sour water and hydrogen rich gas. The Separator is provided with the water boot to collect the water injected for salt removal. The sour water is removed, under pressure, from the Separator boot for treatment in the Sour Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 73

Water Stripper unit. The hydrogen rich gas is recycled via the Recycle Compressor Suction Drum (14-VV-VI-004) and Recycle Compressor (14-KA-RP-002A/B), to upstream of the Combined Feed Exchanger (14-EE-00-001), Makeup Hydrogen rich gas from CCRU is introduced to suction of recycle gas compressor after compressing with make-up gas compressor (14-KA-RP-001A/B). Hydrogen liquid from the Separator and any liquid dropout in the Recycle Compressor Suction Drum (14-VV-VI-004) are combined and go forward to the Stripping Section. Stripping Section The liquid hydrocarbon in the separator is routed under level control through the Stripper feed Bottom Exchanger (14-EE-00-004A/B), where it is preheated before entering the Stripper (14-CC-00-001).The stripper (14-CC-00-001) is reboiled by the Steam Heated Stripper Reboiler (14-EE-00-006).The vapor from the reboiler strips H2S, trace water, light hydrocarbons and dissolved hydrogen from the striper feed. The vapor stream passes overhead to the Stripper Condenser (14-EA-FN-002A/B) before passing to the Stripper Receiver (14-VV-HI-006). Liquid hydrocarbon collected in the Stripper receiver is returned to the Stripper as reflux, by the Stripper Reflux Pump (14-PA-CF-003A/B). Normally, no net overhead liquid product is produced, although a line is provided to allow drainage of hydrocarbon material during shutdown of NHT. There is normally no flow in this line. Any water condensing in the Stripper Receiver collects in the boot and is removed to Sour Water Stripper. Off-gas from the Stripper Receiver is removed under pressure control to amine Absorption Column (14-CC-00-003). The stripper bottom liquid is cooled in the Stripper Feed-Bottoms Exchanger (14-EE-00-004A/B) and then passes to the Platforming Unit. A cooler (14-EE-00-008A/B) is provided to take this liquid to storage tank after cooling. Process Chemistry The main purpose of the Naphtha Hydro-treating Process is to clean-up a naphtha fraction so that it is suitable as charge to a Plat-forming unit. There are six basic types of reactions that occur in the hydro-treating unit. A. Conversion to organic sulfur compounds to hydrogen sulfide B. Conversion of organic nitrogen compounds to ammonia C. Conversion of organic oxygen compounds to water D. Saturation of olefins E. Conversion of organic halides to hydrogen halides F. Removal of organo-metallic compounds Details A) Sulfur Removal For bimetallic Plat-forming catalysts, the feed naphtha must contain less than 0.5 weight ppm sulfur to optimize the selectivity and stability characteristics of the catalyst. In general, sulfur removal in the hydro-treating process is relatively easy, and for the best operation of a Plat-former, the hydro-treated naphtha sulfur content should be maintained well below the 0.5 weight ppm maximum. Commercial operation at 0.2 weight ppm sulfur or less in the hydro-treater product naphtha is common. Typical sulfur removal reactions are shown below. (Mercaptan)

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C-C-C-C-SH + H2 (Sulfide) C-C-S-C-C + 2H2 (Disulfide) C-C-S-S-C-C + 3H2

C-C-C-C + H2S

2 C-C + H2S

2 C-C + 2H2S

(Cyclic Sulfide)

(Thiophenic)

Nitrogen Removal Nitrogen removal is considerably more difficult than sulfur removal in naphtha hydro treating. The rate of denitrification is only about one-fifth the rate of desulphurization. Most straight run naphtha contain much less nitrogen than sulfur, but attention must be given to ensure that the feed naphtha to a bimetallic Plat forming catalyst contains a maximum of 0.5 weight ppm nitrogen and normally much less. Any organic nitrogen that does enter the Platformer will react to ammonia and further with the chloride in the recycle gas to form ammonium chloride. Ammonium chloride will deposit in the recycle gas circuit or stripper overhead system. Ammonium chloride salts can be removed by water washing, but will result in downtown or product to slop to effect the water wash. Ammonium chloride salts can be minimized by maximizing nitrogen removal in the Naphtha Hydro treating unit. Nitrogen removal is much more important when a Naphtha Hydro treating unit processes thermally derived naphtha, as these feed stocks normally contain much more nitrogen than straight run naphtha. The ammonia formed in the denitrification reactions, detailed below, is subsequently removed in the hydro treater reactor effluent wash water. Denitrification reactions are favored more by pressure then temperature

(Pyridine)

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(Quinoline)

(Pyrrole)

C)Oxygen Removal Organically combined oxygen, such as a phenol or alcohol, is removed in the Naphtha Hydro treating Unit by hydrogenation of the carbon-hydroxyl bond, forming water and the corresponding hydrocarbon. Oxygenate removal is favored by high pressure and high temperature

Olefin Saturation Olefin saturation is almost as rapid as desulphurization. Most straight run naphtha contains only trace amounts of olefins, but cracked naphtha usually has high olefin concentrations. Processing high concentrations of olefins in a Naphtha Hydro treating unit must be approached with care because of the high exothermic heat of reaction associated with the saturation reaction. Hydrogenation of olefins is necessary to prevent fouling or coke deposits in downstream unit. Olefins can polymerize at platforming combined feed exchanger and thus cause fouling (Linear Olefin) Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 76

C-C=C-C-C-C + H2 (Cyclic Olefins)

C-C-C-C-C-C (and isomers)

Halide Removal A typical organic chloride decomposition reaction is shown below. C-C-C-C-C-C-Cl + H2 HCl+ C-C-C-C-C-C Metal Removal Most metallic impurities occur at the part per billion (ppb) level in naphtha. The ng these compounds at fairly high concentrations,Up to 5 weight ppm or more, on an intermittent basis at normal operating conditions. The Metallic impurities remain in the hydro treating catalyst when removed from the naphtha. Some commonly detected c catalyst are arsenic, iron, calcium, magnesium, phosphorous, lead, silicon, copper, and sodium. Reaction Rates and Heats of Reaction The approximate heats of reaction (in kJ per kg of feed per cubic meter of hydrogen consumed and relative heats of reaction are: Heat of Reaction Relative Heat of Reaction Reaction rate Desulphurization 8.1 1 10 Olefin Saturation 40.6 5 80 Denitrification 0.8 0.1 20 As can be seen from the above summary, desulphurization is the most rapid reaction taking place, but it is the saturation of olefins which generates the greatest amount of heat. Certainly, as the feed sulfur level increases, the heat of reaction also increases. However, for most of the feed stocks processed, the heat of reaction will jut about balance the reactor heat loss, such that the Naphtha Hydro treating reactor inlet and outlet temperatures are essentially equal. Conversion of organic chlorides and oxygenated compounds are about as difficult as denitrification. Consequently, more severe operating conditions must be used when these compounds are present.

CCR PLATFORM
This section is divided into Reforming:-Hydro treated aphtha from HT section is processed in UOPs Platformer to produce aromatic rich reformate. It has 4 Reactors with continuous circulation of catalyst by adding fresh /regenerated catalyst at the top and withdrawing spent catalyst from the bottom.

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Reformate conditioning and splitting:-Reactor effluent is processed in Debutanizer & Deethaniser to produce Reformate & LPG. The reformate is further split into two fractions viz., light reformate and heavy reformate in Reformate splitter section. Hydrogen recovery and purification:-The hydrogen rich excess gas generated in reforming section is sent to recontacting section where it is compressed and cooled and contacted with separator bottoms liquid to increase reformates and LPG yield. The hydrogen rich gas is further sent to recovery plus section to recover lighter. The excess gas is treated in chloride treater to remove chloride and is further processed in hydrogen recovery section (PSA) to recover hydrogen and sent to existing hydrogen network. PSA off gas is compressed and sent to refinery fuel gas network. Catalyst regeneration:-This section contains continuous catalyst regeneration system, consisting of catalyst transfer systems, lock hoppers, regeneration heaters, reduction heaters, blowers, dust collectors, air dryer, chloride & sulphide injection systems, caustic circulation systems etc. for continuous coke burn, chlorination/oxidation and reduction of spent catalyst. The regenerated catalyst is pneumatically transferred back to Reactor. Convection section of reformer furnace has HP steam generation system. INTRODUCTION ( PLATFORMER SECTION) The catalytic reforming process has been a mainstay in most refineries throughout the world for many years. The original function of this process was to upgrade low octane number straight-run naphthas to higher octane motor fuel blending components by catalytically promoting specific groups of chemical reactions. Naphtha boiling range products from other processes (thermal cracking, coking, etc.) were soon being included in the charge to catalytic reforming units for octane improvement. The reforming application was logically and rather quickly expanded to include the production of specific aromatic hydrocarbons. High-purity benzene, toluene, and mixed xylenes were made available to the chemicals industry from petroleum fractions by the combination of reforming, aromatics extraction, and fractionation. Hydrogen, the by-product from the aromatic producing reactions, was found to be useful in supporting the operation of reformer feed preparation units as well as other hydrotreating units. The light hydrocarbon gases, by- products of the cracking reactions, were generally added to refinery fuel gas systems. Butanes, other cracking by-products, were commonly used in adjusting vapor pressures of gasoline pools. Thus, most refiners and many petrochemicals manufacturers have found the catalytic reforming process an increasingly valuable tool. Hydrotreated naphtha from Naphtha hydrotreater is used as a feed for CCR Platforming unit under MSQU project. Reformate produced in CCR Platforming unit is sent to Reformate Splitter. LPG, Hydrogen, Make-up gas, Fuel gas are also produced in CCR Platforming unit. The capacity of the unit is 600 TMTPA.

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BRIEF PROCESS DESCRIPTION The platformer unit is a section of the MSQU complex, which also includes the Naphtha Hydrotreater (NHT). The platformer is designed to process naphtha from the NHT as feedstock. The platformer is designed to produce maximum yield of aromatic rich reformate, a H2 stream with minimum C5+ content and to recover LPG from the fractionation section which is sent to deethaniser section. The NHT and platformer Units are close-coupled. Hydrogen rich gas from the existing refinery will be imported to the Naphtha Upgrading complex to allow start-up of the NHT and Platforming Unit. Reactor Section:The catalyst is capable of operating over a wide range of temperatures with little adverse effect on product yield and catalyst stability. However very high temperatures will affect the yield and catalyst stability. The flue gases from all heaters are combined and used to generate HP steam in the convection section. This stream is used in reboiler and balance exported to refinery H.P. Header. There are four Reactors (15-RB-00-001/002/003/004) stacked one above the other. The effluent from each Reactor is heated in the interheaters (15-FF-00-002/003/004) prior to entering the next Reactor to maintain the constant inlet reaction temperature, as the reaction is endothermic. The Reactor feed flows radially through the catalyst bed. A small portion of hydrogen-rich recycle gas enters the stacked Reactors at the bottom after being heated in the Reactor purge exchanger (15-EE-00-002) by a portion of the Reactor effluent stream. This gas stream is to purge the hydrocarbon from the spent catalyst before it is regenerated. A portion of the catalyst is continuously withdrawn from the Reactors and is regenerated in CCR regeneration section. The effluent from the Reactor is cooled in the combined feed exchanger against fresh feed as described above. The combined Reactor effluent are further cooled in the product condenser (15-EA- FN-001A/B/C/D/E/F-air cooled) before flowing to the separator. PROCESS CHEMISTRY:The following is a discussion of both naphtha and catalyst chemistry involved in the Platforming process. The subjects of naphtha chemistry and catalyst chemistry have been segregated as much as possible to make the discussion easy to follow. However, the two subjects are necessarily and inherently interrelated and some overlap of subject material has been presented with the assumption that the reader is familiar with basic organic chemistry and the concept of thermodynamic equilibria. For better understanding process principles are also illustrated in figures. All figure as referred in this section are attached after the section. The organization of process chemistry is PLATFORMING HYDROCARBON CHEMISTRY 1. 2. 3. 4. 5. 6. Composition of Feed and Product Platforming Reactions Relative Reaction Rates Heats of Reaction Equilibrium Considerations Effects of Pressure and Temperature on Reaction Selectivity Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 79

7.

Reactor Hydrocarbon Conversion Profiles

PLATFORMING CATALYST CHEMISTRY 1. Dual Function Catalyst Sites 2. Pressure Effects 3. UOP Platforming Catalysts Platforming Reactions The following reactions take place in the Platforming process to an extent dependent on the severity of the operation, the quality of the feed, and the catalyst type. the dehydrogenation reaction is easy to promote and produces by-product hydrogen as well as the aromatic hydrocarbons. This reaction is very endothermic. It is promoted by a metal catalyst function and is favored by high reaction temperature and low pressure. The discussion of catalyst acid and metal functions is contained in the Catalyst Chemistry section. It is now important to only note which reactions are catalyzed by the acid function and which ones are catalyzed by the metal function. b. Isomerization of Naphthenes and Paraffins (1) The isomerization of a cyclopentane to a cyclohexane, shown in Figure -3, must

occur as the first step in converting the cyclopentane to an aromatic. This isomerization involves ring rearrangement and the probability for ring opening to form a paraffin is quite high. Therefore, the reaction of alkylcyclopentanes to cyclohexanes is not 100% selective. The reaction is strongly dependent on the processing conditions. (2) Paraffin Isomerisation, shown in Figure-4, occurs readily in commercial Plat forming operations but at typical operating temperatures the thermodynamic equilibrium is not strongly in favour of the more desirable (higher octane) branches isomers. In motor fuel applications this reaction does made a contribution to octane improvement of the naphtha. Isomerisation reactions result from carbonium ion intermediate reactions. These reactions are promoted by the acid function and are only slightly dependent on operating pressure. c. De-hydrocyclization of Paraffins De-hydrocyclization of paraffins, shown in Figure-5, is the most difficult Plat forming reaction to promote. It consists of a very difficult molecular rearrangement from paraffin to a naphthene, in the case of light paraffins, equilibrium considerations limit this reaction. The paraffin cyclization step becomes easier as the molecular weight of the paraffin increases, because of increased statistical probability for the formation of the naphthene. Somewhat counteracting this effect is the increased probability of the heavier paraffins to hydrocrack. De-hydrocyclization is favoured by low pressure and high temperature. Both metal and acid catalyst functions are needed to promote this reaction. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 80

d. Hydro cracking Because of the strained ring Isomerisation and ring formation reactions that the feed alkylcyclopentanes and paraffins must undergo, and because the catalyst needs to have an acid function, the possibility for acid-promoted hydro cracking, depicted in Figure-6, is strong. Paraffins hydro cracking is relatively rapid and is favoured by high pressure and high temperature. The disappearance of paraffins from the gasoline boiling range via hydro cracking does concentrate aromatics in the product and hence contributes to octane improvement. The reaction does, however, consume hydrogen and result in lower reformat yield. This reaction inturn increases the coke laydown of the catalyst. e. De-methylation De-methylation reactions, shown in Figure-7, generally occur only in very severe Plat forming operations (high temperature and high pressure). Under certain conditions it may occur during the start-up of a semi-regenerative Platforming Unit following catalyst replacement or regeneration. The reaction is metal catalysed and is favoured by high temperature and pressure. It can be inhibited by attenuation of the catalyst metal function by addition of sulfur or a second metal (as in some bimetallic catalysts).

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Gujarat Refinery -1 Catalytic Reforming Unit (CRU)

INTRODUCTION :Catalyst Reforming Unit of Gujarat Refinery was designed & commissioned with Russian collaboration in October 1966. The design capacity of the unit was 3,00,000 MTPA. Since 1968 BT production also started along with MS. Russian catalyst was Changed over to Engle Hard RD-150/RD-150C in 1974. Since 1982, run only for BT production due to the availability of FCC gasoline. Engle Hard RD-150/RD-150C was Changed over to E-301/302 in 1988. Unit was revamped for production of Benzene, Toluene & Xylene in March 1990. The reformer catalyst was changed from mono-metallic to CK-433 (Bimetallic ) catalyst of Ms. Ketjen. The new catalyst is very sensitive to the impurities like Sulfur, Nitrogen, Water, Heavy Metals etc. Therefore, a new pretreater Unit has been set up to remove above Hydro desulfurization catalyst KF-742 of Ketjen of Netherlands is used in Pretreater. Motor driven reciprocating Recycle Gas compressors were replaced by new turbine driven compressor in1998. After completion of 9 years life CK-433 was changed to E-603 in Aug-1999 and the unit has completed 3 regeneration.The pretreater catalyst has been replaced to CDS-NPC7/CDS-LX6T IN DEC-2003. A new FG system V-04 A/B and FO system which supplies oil to Lab/CRU/CCRU has been commissioned in Nov-03. . The old FO tanks E11/E12, FG bullets E114/115 and the connected lines have been decommissioned and dismantled. Naphtha of two cut ranges i.e. 70-900C and 90-1700C cut is processed separately in blocked out operation to produce the reformate specific for Benzene/ Toluene and MS recovery, respectively. During sept. 04,necessary modification done in AU-2 rerun section to enable reformate routing to AU-2 rerun column K-8 & K-9 in succession.With this wide cut naphtha processing in CRU was started , with 70-170 cut drawn from K-7 bottom of AU-2 mixed with 70-90 cut from K-9 top of AU-1 forming the feed to CRU via feed tanks.Separation of BT reformate & MS components from wide cut reformate is done in AU-2 rerun section.

Process In Brief:Pretreater:The process sequence, arrangement of process equipment with major control scheme are shown in Process flow diagram. The fresh feed naphtha coming from feed tank through the pump 21-P01A/B is mixed with the recycle gas. This reactor feed is pre-heated in the feed effluent heat Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 82

exchanger 21-E-01A/B/C and finally heated up to the reaction temperature (305-3350C) in the furnace 21-F-01. Desulfurisation and denitrification reaction take place in the Reactor 21-R-01. The reactor effluents is cooled first in the feed effluent exchanger 21-E-01A/B/C and finally in the water cooled exchanger 21-E-02A/B. Liquid and vapour phases are separated in the drum 21-V-01. A part of vapour is purged to remove light gases from the system and the remaining hydrogen rich stream is recycled to make up for the loss of hydrogen and to maintain hydrogen partial pressure at the desired level in the reactor, a certain amount of make up gas is drawn from the Reformer Section. The mixture of recycle gas and the make up gas is compressed in the compressor 21-K-01A/B & is added to the fresh naphtha feed. A knock out drum 21-V-02 is provided at the compressor suction to minimize entrainment,of liquid droplets to compressor suction.

Auxiliary systems provided are facilities to inject Dimethyl disulfide. REFORMER:The pre-treated stabilised naphtha is pumped by pumps 22-P-01A/B and mixed with the recycle gas coming from 22-K-01. The two phase mixture of combined feed enters the shell side of T-4 & T-5 working in series and heated by the reactor effluent ex R-3/R-4 flowing on the tube side. Preheated feed then enters convection side of furnace P-1A.It then gets further heated in RAD-2 coil followed by RAD-1coil where it is heated to a reaction temp. of 501/5060C and introduced into the first reactor (R -1). Reactions being endothermic, the reactor outlet temp. will drop. This stream is again heated to the reaction temp. of 501/506 in a inter-heater (22-F-01) and fed to a second reactor (R-2). In this reactor also outlet temp will drop. Reactor outlet product is again heated up to reaction temp. inter-heater- II(P-1B)(RAD-3) and fed to the reactors R-3 & R-4 working in parallel. Part of the reactor effluent from the reactor R-3 & R-4 is sent to the stabiliser reboiler T-8 and again joins the rest of the effluent after exchanging heat in T-8. The effluent mixture then enters the tube side of T-5/T-4 working in series.The effluent is further cooled in water cooler T-6 and T-7 in series. The water-cooled effluent ex T-7 flows to product separator C-2 where liquid and gas phases are separated. The gas flows to second separator C-3 where any liquid carryover is knocked off. Part of the gas from C-3 is diverted to fuel gas, maintaining system pressure at 16.0 to 18.0 kg/cm2g. The rest of the gas is compressed in recycle gas compressor and recycled back, keeping specified mole ratio. A part of compressed gas is diverted to Pretreater unit as make up gas. The liquid from separator C-2 is preheated in K-2 feed / bottom exchanger T-10 and fed to the stabiliser K-2. Stabilised reformate is cooled in T-10 and water cooler T-11 and sent to MS Tank in OM&S via line no-45 during MS run, to UDEX feed tanks during BT run, to K-8 Column in Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 83

AU-2 rerun section during combined mode operation to further seperation of BT reformate and MS component.

Process Chemistry:Hydrotreating catalyst normally contains Cobalt Molybdenum Oxides and Nickel Molybdenum Oxides. Structurally Hydrotreating catalyst may be defined as a porous - AL2O3 support which carries molybdenum oxide as a bound monolayer. Cobalt or Nickel promoter ions are deposited on to the surface of molybdenum alumina structure. To obtain maximum activity of hydrotreating, metal oxides have to be converted into sulphides and to be maintained in sulphide phase during presulfiding procedure either with the feed itself or with the external sulfiding agent. The reaction mechanism of the conversion of metal oxides into sulphides in not known exactly. It has sufficiently been proved that under certain conditions, especially at high temp. The metal oxides are partially reduced by hydrogen, which result in loss of activity. Reduction of the metal oxides to metals or lower valence oxides becomes significant at catalyst temp. above 3000C. Once reduction has occurred, it is practically impossible to convert the metals to their sulphides. If not enough sulphur has been added to the catalyst, before the catalyst temp. is set at operating level, the same irreversible reduction may occur. The following scheme of completing reaction is assumed including reactions of regeneration. Metal Oxides H2 Metal or lower valence state Oxides Hydrotreating reactions Predominantly, there are two types of reactions which occur during pretreatment. Hydro Desulfurization The sulfided catalyst reacts with organic sulphur to give inorganic sulphur (H2S) and hydrocarbon at high temp. and pressure. Metal sulphide H2S slow

+ 4H2

H2S + C4H10(-67.0Kcal/ Mole)

C2H5SH + H2 C2H6 + H2S(-16.8 Kcal /mole) Ethanethiol Ethane Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 84

C2H5S C2H5 + 2H22C2H6+H2S (-28.0 Kcal/mole) Diethyl sulfide Ethane

2-3 molecules of hydrogen are consumed per atom sulfur removed. The reaction rate for each compound decreases with its molecular weight. In general, the sulphur present in aromatic type structure is more difficult to remove than in straight chain molecules. Hydrodenitrogenation Hydro denitrogenation occurs simultaneously with hydro desulfurization. Nitrogen containing compounds are converted to saturated hydrocarbons and ammonia.

+ 5H2 N Pyridine

C5H12 + NH3 n-pentane C3H7

+ 4H2 N Quinoline Propyl benzene

+ 2NH3

+ 4H2 N H Pyrrole

C4H10 + NH3 Butane

In practice an average of 4 molecules of hydrogen are consumed per atom of nitrogen. Hydrogenation Of Aromatics Although it is not desired in most cases some hydro-generation of aromatics will occur in hydrotreating process

Benzene

3H2 Cyclohexane

Hydrogenation Of Olefins Olefins formed during cracking or present in feed, are instantaneously saturated with hydrogen. Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 85

C5H10 + Pentene

H2

C5H12 Pentane

REFORMING Introduction Reforming process is carried out at relatively high temp. & Pressure by passing the Naphtha feed stock over a bed of catalyst. The catalyst loaded in CRU reactors is E-603 of ENGELHARD, which contains 0.3 % Platinum 0.3 % Rhenium Typical operating condition of the Reformer are Reactor inlet temp. : 5010C - 5160C Pressure: 16.90 kg/cm2g In the reforming process, structures of Hydrocarbon molecules are rearranged to form more of higher-octane aromatics. Reactions Predominantly, there are five different types of reactions which occur during reforming. 1. 2. 3. 4. 5. Aromatization of Naphthenes & Paraffins Isomerization of Naphthenes & Paraffins Hydrocracking Hydrogenation of Olifins Desulfurization.

Aromatization Of Naphthenes & Paraffins A) Dehydrogenation Of Naphthenes

Cyclohexane CH3 Benzene

+ 3H2

CH3 + 3H2 Vocational Training Report | Indian Oil Corporation, Gujarat Refinery 86

Methyl Cyclohexane

Toluene

The dehydrogenation reaction are highly endothermic and cause a decrease in temp. the reaction proceeds. They have the highest reaction rates and they occur mostly in the first two reactors. B) Dehydrocyclization Of Paraffins C6H14 n-Hexane Cyclohexane + H2 Benzene + 3H2

This reaction is also endothermic and has low reaction rate Isomerization Of Naphthenes & Paraffins A) Isomerization Of Naphthenes CH3

Methyl Cyclo pentene Cyclo hexane

CH3

CH3

CH3

Dimethyl Cyclo pentene Isomerization Of Paraffins

Methyl Cyclo hexane

n-Heptane

--------- ---------

Iso-heptane

These reactions are fairly rapid. The heat effects of Isomerization are very small. HYDROCRACKING

C10H22 + H2 n-Decane C8H18 + H2 n-Octane

C5H11CH3 + C4H10 Methyl Butane Pentane C3H8 + C5H10 Propane Pentane

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These reactions are highly exothermic. They are relatively slow reactions and there fore most of the hydrocracking of straight chain paraffins result in Octane improvement but hydrocracking of Naphthenes will reduce the Naphthenes potential used for conversion to Aromatics. Hydrogenation Of Olefins Olefins formed during cracking or present in feed are instantaneously saturated with Hydrogen.

C5H10 + H2 Pentene

C5H12 n-pentane

DESULFURIZATION

+ 5H2 S Thiophin

H2S

C4H10

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GENERAL SAFETY REGULATIONS

Smoking is not allowed in any part of the refinery area, except in the smoking booths specifically constructed for this purpose. When any dangerous/unsafe condition is observed it should be immediately reported to your supervisor and/or Fire and Safety Division. Employees should be careful to clean the job areas as soon as the job is completed. Good housekeeping will eliminate any unnecessary hazards causing accidents. Where walkways are provided, use them instead of shortcuts. If you are to use the road way, keep to right side so that you can see the approaching vehicle. All stairways, platforms and walkways must be kept clean at all the times. Exercise care in walking and in moving about your work, avoid slipping, tripping or falling. Do not attempt major work while standing on lines or fittings. Avoid running during normal operations. Walking on the pipelines is prohibited. Do not attempt to operate or set in motion any machine or equipment to which you are not assigned. Compressed air must not be used for blowing dust out of the clothing. Never look directly into the ARC produced while welding without proper eye protection. Falling objects have caused many injuries. Handle material with care. Keep check of suspended loads at all the times. Do not use defective equipment of any kind. Keep the fire-fighting equipments free of obstructions, as these are required to be used in the emergencies. In case of an acid/caustic splash, wash yourself with copious quantity of water and report immediately to medical centre for further treatment and advice. No clothing or the inflammable material should be dried out on steam lines or any other hot equipment.

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 Goggles or shields must be used when working on emery wheel, chipping, sand blasting or under other circumstances where there are possible eye hazards. Sample bottles should not be used for any purpose other than taking samples. Vehicles of all types must be equipped with good exhaust and muffler system before entering in the refinery area. Protective valve caps must always be placed on all gas cylinders (oxygen, acetylene, ammonia, carbon dioxide, LPG, chlorine) except when in use. Gas cylinders should never be dropped especially from trucks or platforms. Always use a special carrier for hoisting the gas cylinders. All belt couplings and moving parts of the machine must be securely guarded at all times. It is strictly prohibited to use gasoline or any other highly inflammable liquid or corrosive chemicals such as caustic soda or acid for cleaning purpose. When electrically driven pumps, compressors etc. are shut down for repairs, the electrical circuit must be isolated before repairs commence. All personnel must have knowledge of the fire fighting and should familiarize themselves with extinguisher and steam points/other equipments located in the refinery area. All persons should know how to call fire brigade and the ambulance. Even while working with the fire permit and clearance certificate, stop work and immediately report to the supervisor, in case hazardous conditions are noticed.

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