VOCATIONAL TRAINING REPORT

INDIAN OIL CORPORATION LTD.

GUJARAT REFINERY
(20th MAY-15th JUNE)

Submitted by:
Abhishekh Patil
Dhanashree Rakhade
Hrishikesh Mohod
Shruti Koshta
Simran Shrivastava
Vaibhavi Dabli

B.Tech 3rd year Chemical Engineering

Laxminarayan Institute of Technology, Nagpur

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 PREFACE

Industrial training plays a vital role in the progress of future engineers. Not only
does it provide insights about the future concerned, it also bridges the gap
between theory and practical knowledge. We were fortunate that we were
provided with an opportunity of undergoing industrial training at INDIAN OIL
CORPORATION LTD., KOYALI. The experience gained during this short period was
fascinating to say the least. It was a tremendous feeling to observe the operation
of different units and processes. It was overwhelming for us to notice how such
a big refinery is being monitored and operated with proper coordination to
achieve desired results. During our training period we realized that in order to
be a successful chemical engineer one needs to put his/her concepts into action.
Thus, we hope that this training serves as a stepping stone for us in future and
help us carve a niche for ourselves in this field.

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 ACKNOWLEDGEMENTS

We express our indebtedness and gratitude for many individuals who

have helped to shape this report in its present form cannot be adequately
conveyed in just a few sentences. Yet we must record our immense gratitude to
those who helped us to undergo the valuable learning experience at IOCL
Vadodara.

We are highly obliged Mr. Vijender Kumar, Training and Development

department for providing us this opportunity to learn at IOCL. We thank Brijal
Madam for briefing us and introducing us to refinery working guidelines.

Lastly, We are thankful to god, our parents, our family and friends for support
and cooperation throughout the training.

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 CERTIFICATE

This is to certify that this industrial training report was submitted by the
following students under my guidance during the period.The appropriate
references for the data gathered from IOCL and other sources for the
preparation of report have been incorporated at the end of the report.

Abhishekh Patil
Dhanashree Rakhade
Hrishikesh Mohod
Shruti Koshta
Simran Shrivastava
Vaibhavi Dabli

Mr. VIJENDER KUMAR Date:15 JUN 2019

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 Table of Contents

Sr. No. Title Page No.

1. Introduction
1.1 Refineries 7-8
1.2 Gujarat Refinery: An overview 9-13
1.3 Units at Gujarat Refinery 12—13
1.4 Products and its uses 11
2. Atmospheric unit-3 (AU-3)
2.1 Introduction 14
2.2 Feed and product specification 14
2.3 Process Description 14-18
3. HYDROCRACKER UNIT (HCU)
3.1 Introduction 19
3.2 Process 19-24
4. General Safety Regulations 25-27
5. Project 28-34
6. Result and Conclusion 36

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 INTRODUCTION

Indian Oil, the largest commercial enterprise of India (by sales turn over), is
India’s sole representative in Fortune's prestigious listing of the world's 500
largest corporations, ranked 189 for the year 2004. It is also the 17th largest
petroleum company in the world. Indian Oil has a sales turnover of 1, 20,000
crore and profits of 8,000 crore. Indian Oil has been adjudged second in
petroleum trading among the 15 national oil companies in the Asia-Pacific
region. As the premier National Oil Company, Indian Oil’s endeavor is to serve
the national economy and the people of India and fulfill its vision of becoming
“an integrated, diversified and transnational energy major."
Beginning in 1959 as Indian Oil Company Ltd, Indian Oil Corporation Ltd. Was
formed in1964 with the merger of Indian Refineries Ltd. (Est. 1958). As India's
flagship national oil company, Indian Oil accounts for 56% petroleum products
market share, 42% national refining capacity and 67% downstream pipeline
throughput capacity. IOCL touches every Indian’s heart by keeping the vital oil
supply line operating relentlessly in every nook and corner of India. It has the
backing of over 33% of the country’s refining capacity as on 1st April 2002 and
6523 km of crude/product pipelines across the length and breadth of the
country. IOCL’s vast distribution network of over 20000 sales points ensures that
essential petroleum products reach the customer “at the right place and at the
right time”
Indian Oil controls 10 of India's 18 refineries at Digboi, Guwahati, Barauni, Koyali,
Haldia, Mathura, Panipat, Chennai, Narimanam and Bongaigaon - with a current
combined rated capacity of 49.30 million metric tones per annum (MMTPA) or
990 thousand barrels per day (bpd).
Indian Oil’s world-class R&D Center has won recognition for its pioneering work
in lubricants formulation, refinery processes, pipeline transportation and bio-
fuels. It has developed over 2,100 formulations of SERVO brand lubricants and
greases for virtually all conceivable applications-automotive, railroads, industrial
and marine-meeting stringent international standards and bearing the stamp of
approval of all major original equipment manufacturers. The center has to its
credit over 90 national and international patents. The wide range of
brand lubricants, greases, coolants and brake fluids meet stringent international
standards and bear the stamp of approval of all major original equipment
manufacturers.

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Indian Oil operates 17 training centers throughout India for up-skilling, re-skilling
and multi-skilling of employees in pursuit of corporate excellence. Among these,
the foremost learning centers-the Indian Oil Institute of Petroleum
Management at Gurgaon, the Indian Oil Management Center for Learning at
Mumbai, and the Indian Oil Management Academy at Haldia-have emerged as
world-class training and management academies. Indian Oil Institute of
Petroleum Management, the Corporation's apex center of learning, conducts
advanced management development programmers in collaboration with
reputed institutes. It also offers a unique mid-career International MBA
programmed in Petroleum Management.
Indian Oil aims at maintaining its leadership in the Indian hydrocarbon sector by
continuous assimilation of emerging Information Technology and web- enabled
solutions for integrating and optimizing the Corporation's hydrocarbon value
chain. It is currently implementing an IT re-engineering project titled Manthan,
which includes an Enterprise Resource planning (ERP) package which will
standardize and integrate the Corporation's business on a common IT platform
through a robust hybrid wide area network with appropriate hardware.

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 Refineries

Digboi Refinery, in Upper Assam, is India's oldest refinery and was commissioned
in 1901. Originally a part of Assam Oil Company, it became part of Indian Oil in
1981. Its original refining capacity had been 0.5 MMTPA 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 1 January 1962.

Barauni Refinery, in Bihar, was built in collaboration with Russia and Romania. It
was commissioned in 1964 with a capacity of 1 MMTPA. Its capacity today is 6
MMTPA.

Gujarat Refinery, at Koyali in Gujarat in Western India, is Indian Oil’s largest

refinery. The refinery was commissioned in 1965. It also houses the first hydro
cracking unit of the country. Its present capacity is 13.70 MMTPA.

Haldia Refinery is the only coastal refinery of the Corporation, situated 136 km
downstream of Kolkata in the Purba Medinipur (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 MMTPA capacity was built and commissioned in 1998. Panipat Refinery has
doubled its refining capacity from 6 MMT/yr to 12 MMTPA with the
commissioning of its Expansion Project.

Bongaigaon Refinery is the eight refinery of Indian Oil. It became the eighth
refinery of Indian Oil Corporation Limited after merger of Bongaigaon Refinery
& Petrochemicals Limited with IOCL w.e.f. 25th March 2009. It is located at
Dhaligaon in Chirang district of Assam, 200 Kms west of Guwahati. The present
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crude processing capacity of the refinery is 2.35 MMTPA. The refinery has two
Crude Distillation Units of 1.35 MMTPA and 1.00 MMTPA capacities, two
Delayed Coker Units each of 0.5 MMTPA capacity, one Coke Calcinations Unit of
0.075 MMTPA and Catalytic Reformer of 160,000 MTPA naphtha feed capacity
and an LPG Bottling Plant.
It is believed that the future IOCL refinery will be Paradeep Refinery. It is
expected to be handover at 2012.

Subsidiary refineries — Chennai Petroleum (9.5 MMTPA)

Indian Oil controls 10 of India's 18 refineries with a current combined rated
capacity of 49.30 million metric tons per annum (MMTPA). All refinery units are
accredited with ISO 9002 and ISO 14001 certifications.

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 GUJARAT REFINERY: AN OVERVIEW

The Gujarat Refinery at Koyali in Gujarat in Western India is Indian Oil’s largest
refinery. The refinery was commissioned in 1965. Its facilities include five
atmospheric crude distillation units. The major units include CRU, FCCU and the
first Hydro-cracking unit of the country. Through a product pipeline to Ahmadabad
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.
When commissioned, the Gujarat refinery had a design capacity of 3.0 MMTPA. The
capacity has since been increased to its present capacity of 13.70 MMTPA by low
cost debottlenecking. The company has already commissioned the facilities for
MTBE and Butene-1production.The refinery also produces a wide range of specialty
products like Benzene, Toluene, Food Grade Hexane, solvents, LABFS, etc. The
Gujarat Refinery achieved the distinction of becoming the first refinery in the
country to have completed the DHDS (Diesel Hydro De-sulphurisation) project in
June 1999, when the refinery started production of HSD with low sulphur content
of 0.25% wt (max.).
A project for production of high value LAB (Linear Alkyl Benzene) which is one of
the major raw materials used in manufacturing detergents) from kerosene streams
has been completed recently and started on 15th August, 2004. In order to meet
future fuel quality requirements, MS quality improvement facilities are planned to
be installed by 2006.
Some of the salient features of Gujarat Refinery are:
1) First Riser Cracker FCCU in the country
2) First Hydro Cracker in the country
3) First Diesel Hydro Desulfurization Unit in the country
4) First spent caustic treatment plant in refineries
5) First automated rail loading gantry
6) First LPG mounded bullets in Indian refineries
7) State-of-the-art CETP

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8) Quality Management System (ISO-9001:2000)
9) Environmental Management System (ISO– 14001)
10) International Safety Rating System (ISRS) LEVEL 9 (Highest) First organization in
country; one amongst 30 refineries in world

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 PRODUCT END USES
LPG Cooking Gas (marketed as ‘INDANE’)
Benzene Raw material for petrochemicals
Toluene Raw material for petrochemicals
Naphtha Raw material for petrochemicals
Motor Spirit(90 Octane) ‘Petrol ‘for vehicles
Aviation Turbine Fuel(ATF) Fuel for jet aircraft
Superior Kerosene (SK) Illuminant, domestic purpose
High Speed Diesel (HSD) Diesel locos, trucks, buses, ships
Light Diesel Oil (LDO) Small engines attached to irrigation
Low Sulphur Heavy Stoke (LSHS) Fuel
pumpsin thermal power stations
Fuel Oil(FO) Industrial Furnaces/Boilers
Bitumen Road surfacing
n-Heptane As solvent
ARO Used in aluminum rolling industries
Linear Alkyl Benzene (LAB) Detergent Manufacture
Butene Co-polymer for producing
polyethylene, Polypropylene
Methyl Tertiary Butyl Ether (MTBE) Blending in gasoline for increasing
octane number and oxygen content.
Food Grade Hexane(FGH) Solvent for oil seed extraction.
Glues/Adhesives for footwear
Polymerization reactions in
industries like Pharmaceuticals &
printing ink. Retreading of cartyres

Sulphur Sulphuric acid and tyre manufacture

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VOCATIONAL TRAINING REPORT
About Residue Upgradation Unit

The present operation of Gujarat Refinery is constrained by the restriction in

crude throughput due to high (24%) generation of black oil (LSHS).
The Refinery thru-put is contained at 12.5 MMTPA against the installed capacity
of 13.7 MMTPA.
The secondary processing units (FCCU and HCU) installed at the Refinery are not
able to handle material heavier than VGO. Such residues can be handled by using
RDS, RFCC-Indmax or Coker units.
The absence of these units is limiting the High Sulphur Crude processing (26%)
abilities of the refinery which is much cheaper than the Low Sulphur crude.
In order to increase the profitability of Gujarat Refinery and to ensure full capacity
utilization residue processing unit is essential.
The auto fuel policy of The Government of India envisages supply of Euro III and
Euro IV standard fuels to whole of India by April, 2010.
In order to meet the target, MS/HSD quality improvement Project has to be
initiated.

The Residue Up gradation and MS/HSD Quality Improvement Project (RUP) has
been conceptualized.

The objectives of RUP can be summarized as under:

1. Utilization of 100% installed capacity crude throughput
2. Building facilities to meet Euro –III/IV equivalent MS/HSD by April 2010
3. Improvement in distillate yield trough black oil up gradation
4. Maximization of HS crude processing
5. Minimum investment

Coker configuration was found to be most suitable for Gujarat Refinery due to the
following advantages:
1. 100% utilization of installed capacity of crude throughput
2. 58% HS crude processing
3. 75% distillate yield
4. Lowest capital cost (Capex & Opex )

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Units at the South Block :

1) DHDT (Diesel Hydro treating Unit):

It is designed to desulphurize feed to produce EURO IV grade diesel in
which sulphur concentration is not more than 50 ppm.

2) HGU – III (Hydrogen Generation Unit – III):

Hydrogen is produced in this unit from feed to meet the hydrogen demands
of other units (mainly DHDT and VGO–HDT)
3) ISOM:
Long, straight chain hydrocarbons are converted by isomerisation into
branched compounds, thus increasing the octane number for a fuel.

4) SRU (Sulphur Recovery Unit):

Sulphur mainly in the form of H2S which is produced in other units is
treated for recovery and subsequent further use.

Units at the North Block:

1) DCU (Delayed Coker Unit)

Concept of delayed coking is used to lower carbon to hydrogen ratio and
obtain various products that can be used as feedstock for other units or
sent for dispatch.

2) VGO – HDT (Vacuum Gas Oil – Hydro treating Unit)

Vacuum gas oil from Vacuum Distillation Unit and Coker gas oil from DCU
hydro treated to remove sulphur and nitrogen till their concentration is no
more than 500 ppm.

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VOCATIONAL TRAINING REPORT
 ATMOPHERIC UNIT 3

Purpose of Unit: To separate valuable products of crude oil.

Feed: Feed is mix of
1. North Gujarat (NG)
2. South Gujarat (SG)
3. Imported (Imp)
Capacity: 3.0 MMTPA
Basic Principle: Distillation is an operation of major interest in this unit.
Various compounds split according to their relative volatility.
Products:
1) LPG
2) Light Naphtha
3) Heavy Naphtha
4) ATF/Kerosene
5) Gas Oil
6) Reduced Crude oil (RCO)
Process description:
Basic operations in Atmospheric unit (AU) are as follows:-
 Crude Preheating And Desalting
 Crude Heating In Charge Heater
 Atmospheric Distillation
 Naphtha Stabilization
 Diesel Stripper
 KeroStripper

Atmospheric unit is divided into various subsections as given below.

 Crude Preheat Train I (Old & New)
 Crude Desalter
 Crude Preheat Train II(Old & New)

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  Crude Charge Heater
 Atmospheric Distillation Column
 Naphtha Stabilizer
 Product Cooling And Run Down System

Crude preheater train I

Crude oil enters preheated train 1 from Storage tank by booster pump pipeline
include control valve preheater trains utilize heat of outgoing products from
fractionator.

Preheat train one stop to pass year income includes splits into two streams and a
10 required preheating temperature. Decreasing viscosity and increasing fluidity
of crude so that it can be mixed with DM water properly.

Desalter operation
Preheat train one crude mixes with desalting water by mixing valve in upstream of
Desalter. Here demulsifying agent, corrosion inhibitor and caustic solution are
added.

 Emulsifying agent breaks the water oil emulsion.

 Caustic solution reacts with acid present in crude and gives salt and water
as product which can be removed by water. caustic is added upstream of
Desalter to remove nathanic acid whereas NH3 is added in downstream to
remove HCL vapours generated due to hydrolysis of magnesium chloride
 Desalter works with the help of High Voltage created by submerged
electrode in the tank
 It works with pressure around 12.5 kg per CM square
 2 Desalter are arranged in parallel.
 Salt dissolve in water
 The interface is there between oil and water. The salted water is
continuously flowing out from the bottom of the tank which should not be
hazy. Oil in upper portion in a tank is the suction for Pump 2.

The operational variables for Desalter are

1. Slop oil addition

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VOCATIONAL TRAINING REPORT
 2. Feed rate
3. Water injection
4. Temperature (120 – 140 oC)
5. Pressure (2-3 kg/cm2 above vaporization pressure )
6. Interface level (85-105cm below lower electrode)
7. Chemical agent
8. Voltage (18KV)
9. Amperage (150A)
10.pH (6.5-8.5 normal)
11.Solids at water-oil interface

Crude preheat train II(old and new)

This pump sends the crude to the preheater train 2.Here crude father artist the
high temperature around 270 degrees C.

Atmospheric distillation unit

Atmospheric distillation unit consist of 2 main distillation columns

1. Pre topping Column

Preheated crude is the end sent to pre topping column K1 the pre topping column
is in vicinity of the heat exchangers so that temperature loss can be minimum.

Column Specification:-

No. of trays = 29 trays (1-8 sieve trays and 9-29 valve trays)
Top pressure = 2.2 – 2.9 kg/cm2
Feed Tray = 8th tray from bottom

The top product of column K1 is LPG along with light naphtha. The bottom product
at about 204 OC is pumped to the furnaces F1, F2, F3 working in parallel through
heat exchangers to heat the crude to 370 OC.

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VOCATIONAL TRAINING REPORT
2. Fractionation Column
The feed to column K2 is introduced in flash zone of column. In flash zone of K2 all
products except RCO go in vapor form in upper section whereas RCO drops in
stripping section of K2. Vapours rise through upper section of column and are
fractionated and withdrawn as side cut from column K2.

Column Specification:-

No. of trays = 41 trays (1-6 sieve trays and 7-41 valve trays)
Top pressure = 0.6 kg/cm2
Feed Tray = 6th tray from bottom

Side stream of KERO CR from the tray#26 is drawn from the column K2 and is
pumped to the heat exchanger E-104A/B via pump P-302 A/B. the heat of the
stream is utilized to heat of the incoming feed stream for column K1 and then it is
been sent back to column K2 at 165 degree Celsius on the tray#31.

From the top of column K2, gasoline vapor enter into 4 sets of condenser T-
8A/B/C/D and after condensing are collected in reflex drum E-2. A part of E2
gasoline is put back into the column as a reflex and balance is sent to naphtha to
run down.

Heavy naphtha stripper: First side cut from 165OC is drawn and sent to stripper
column K3A. Overhead vapor are sent back to column K2. Here reboiler is used to
strip out the lighter compounds of Light naphtha. Some portion of the bottom
product is also send back to column K2 as Reflux and other portion of the heavy
naphtha is sent to the storage

Kerosene stripper: Second Side cut from 28th tray at 208 OC is drawn and is sent to
stripper column K3C. The overhead vapor of column K3C sent back to the column
K2 whereas the bottom product is sent by sent to the run down.

SRGO is drawn as third side cut from column K2. SRGO enters the bottom section
of K3 stripper. SRGO from stripper is pump to storage after heat exchanger with
the crude, K4 feed and circulating water.

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AHURALAN (Corrosion Inhibitor) is dozed at the top of the column to arrest
corrosion and Ammonia solution is dozed at vapor outlet line to maintain sour
water pH level at 6 to 6.5

Dozing Daily
Sr. No. Chemical
Concentration Requirement
1. AHURALAN 3-5 ppm 7 Kg
2. Caustic 10-15 ppm 200 Kg
3. Ammonia 10-15 ppm 13 Kg
4. Demulsifier 5-6 ppm 65 Kg

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 HYDRO CRACKER UNIT

Purpose of unit: To convert heavy oils to lighter fractions.

Feed: Vacuum Gas Oil
Product:
1. FUEL GAS
2. LPG
3. LIGHT NAPTHA
4. KEROSENE
5. ATF
6. HSD

What is Hydro cracking?

Hydro cracking is a catalytic process that converts heavy oils to lighter fractions
primarily by means of aromatic saturation, cracking, and isomerization reactions in
the presence of hydrogen .It is one of two major conversion processes used in
modern refining.

General Process Description:

In Hydrocracker Unit , the Vacuum Gas oil (VGO) is taken as feed and
subjected to cracking in two stage reactors over catalyst beds in the presence of
Hydrogen at the pressure of 170Kg/cm2 & temperature of 385°C to 441°C. The
cracked products are separated out in different fractions.

In atmospheric fractionating section while light ends are recovered in LPG

Treating section. The unit consists of following section:

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 (1) First Stage Reactor section

(2) Second stage Reactor section

(3) Atmospheric Fractionation section

(4) Light ends recovery and LPG Treating section

First Stage Reactor section:

Hot Vacuum Gas Oil (LVGO & HVGO) from feed preparation unit at 165°C is received
in vessel VV-00l while remaining feed stock (VGO) come out from storage tank
through feed pump in the form of cold feed which is at about 90°C.Cold VGO is
heated in an heat exchanger 06-EE-030 where the temperature increases from 90°C
to 120°C and Aviation Turbine Fuel (ATF) is used to increases the temperature of
VGO from 120°C to 165°C in an heat exchanger 06-EE-001 before reaching VV-00l.
In vessel VV-00l, Mixing of both VGO coming from storage tank and FPU Unit taken
place. The pressure in this vessel is about 1.2-1.4 Kg/Cm2 .The pump 06-PA-001
take suction from 06-VV-001 and discharges raw oil at the pressure of 9 kg/cm2 to
heat exchanger 06-EE-002, where it is heated from the temperature of 165°C to
200C with the help of atmospheric column pump around. VGO feed is subsequently
filtered on 06-GN-001,where particulates of size more than 25 microns are
removed to avoid plugging of catalyst in the reactor top bed.
The filtered feed from 06-GN-001 is taken in the vessel 06-VV-002 and flow is
controlled by level controller LlC-3302 of filtered of surge vessel. The pressure in
this vessel is about 6.5-7.5kg/cm2 by fuel gas/hydrogen with the help of two
controllers PlC3301A and PIC-33028. Now, Filtered VGO from vessel 06-VV-002 is
pumped through reciprocating pump 06-PA-002 by increasing pressure from
7.5Kg/cm2 to 180kg/Cm2.It mixes with feed gas (make up hydrogen and recycle
hydrogen) before entering heat exchanger 06-EE-003A/B, where it exchanges heat
with first stage reactor effluents & temperature of mixed feed increases from 200°C
to 363°C.After that, feed is sent to the furnace where temperature maintain at
about 385°C.
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First stage reactor furnace 06-FF-001 is a natural draft twin cell heater. It includes
24 burners in each cell. The VGO feed and hydrogen is heated in radiation section.
First stage reactor is designed to operate at the temperature about 385°C to
413°C.The various Hydro cracking reactions taken place on catalyst beds are
exothermic in nature, thus the outlet temperature of each of the three beds is more
than the inlet temperature . As first bed outlet is second bed inlet, second bed
outlet is third bed inlet, the reactants must be quenched (cold) to bring down the
desired temperature for reactions in successive bed. Quenching is done by part of
recycle gas (H2 gas, methane, ethane) from compressor KA-001 discharge and
injected between beds 1 and 2 and beds 2 and 3.Temperature rise across any bed
should not exceed more than 28°C for desired reaction and inlet temperature to
2nd and 3rd bed to be kept same.
Two phase reactor effluent in the separator present at about temperature of 413°C
to 441°C It is cooled to 260°C in an effluent exchanger EE-003A/B. The cracked
Products are further cooled to 225°C by exchanging heat with boiler feed water
(BFW) in an exchanger 06-EE-004.ln 06-EE-004 about 12MT/hr.
In cold low-pressure separator (CLPS), The Reactor effluents are further cooled
from 225°C to 143°C by exchanging heat with liquid in a VV-009 in an exchanger EE-
005.
Now, air cooler 06-EA-001 is used for purpose of cooling of reactor effluent from
the temperature of 143C to 650C with the help of injection water system.
Gas phase separated out from hydrogen mainly consists of hydrogen with small
amount of methane, ethane, propane, butane, etc .which depends on
temperature.
Pressure recovery Turbine (PRT) 06-PT-001 is used to recover excess power of
about 400 KW/hr.
Recycle gas Compressor: The recycle gas (hydrogen, methane, and ethane) from
VV-003 is circulated by steam driven centrifugal compressor. Major portion of
discharge of compressor along with make-upH2 joins oil feed up stream of the
feed/ effluent exchanger EE-003.

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ATMOSPHERIC FRACTIONATION SECTION

Hydrocracker unit consists of four units out of which atmospheric fractionation

section is one.
Feed of the atmospheric fractionation section is drawn from the first stage reactor
which passes from the 06-VV-009 CLPS of the second stage reactor section where
the lighter product (lighter hydrocarbon, methane, ethane) is separated and sent
to light ends recovery and LPG treating section further the remaining part that is
liquid hydrocarbon is passed through heat exchangers 06-EE-005 and also through
06-EE-007 where the temperature rises from 200°C to 256°C.
Now the feed enters into atmospheric fractionation section where it is passed
through heat exchanger 06-EE-010 and further passed through furnace (06-FF-003
fractionation feed furnace). The feed enters into the fractionation column where
different products are separated as per their volatility.

LIGHT ENDS RECOVERY AND LPG TREATING SECTION

Light naphtha from Atm. Fractionator overhead section is pre heated to 59 Deg C
in exchanger EE-021 by naphtha stabilizer bottom product before entering
deethaniser column. The deethaniser column is provided with 34 valves trays. The
feed enters above tray-24. Deethaniser removes gases lighter than ethane, H2S and
water from unsterilized naphtha.
Cooled light naphtha (sponge oil) is combined with deethaniser overhead vapors 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°C by TIC8101 on outlet of cooler which controls the flow of
cooling water in the cooler. The vapors from reflux drum are sent to fuel gas
treating section. Separated water is sent to sour water stripper under interface
level control. Total hydrocarbon from the reflux drum is pumped back to
deethaniser column.

The vacuum column pump supplies heat to the deethaniser reboiler EE-023. The
reboiler is a vertical exchanger located adjacent to the column.

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A water draw off pot VV-015 is provided to remove any water which may
condensed during start up or upset conditions. Deethaniser bottom is pumped to
naphtha stabilizer CC-008.
Stabilizer column 06-CC-008 separates LPG from light naphtha. It is provided with
44 valves trays for fractionation. Unsterilized naphtha at 130°C enters the column
above tray 27. The overhead vapor from stabilizer column is totally condensed in
an air cooler 06-EE-008. The stabilizer overhead pressure is maintained at
12.3Kg/cm2. The sour gas from reflux drum is sent to interstage K.O.D.
Condensed LPG is pumped by 06PA-016 and divided into two streams. One stream
under flow control FlC-8301 is sent back as reflux to top of column to maintain
overhead temperature of 76°C. Other stream is product LPG which is sent to LPG
treating section under reflux drum.
Light Naphtha is a bottom product obtained from stabilizer, cooled from 162°C to
1490°C in an exchanger 06EE-021 by heating up the deethaniser feed. The Light
Naphtha is further cooled to 650°C in an air cooler 06-EE-009. Part of light naphtha
called sponge oil from air cooler is pumped by 06-PA-017 and sent to deethaniser
overhead. Remaining amount of light naphtha is cooled in water cooler 06-EE-026
upto 400°C. Then it is sent to storage tank.

SECOND STAGE REACTOR

The unconverted VGO from the Vacuum Fractionator residue at 376°C is then
boosted to 9kg/cm2 pressure by the PA-039 and made to exchange heat with
Atmospheric fractionators feed in EE-0l0 and then goes at 288°C to suction feed
pump PA-00SA/B. The feed gas (recycle gas + make up H2) after getting heated in
EE-009 at 176°C measures by Tl-5103 mixes with liquid feed. Bypassing of feed gets
necessitated to have a good control over the reactor feed temperature through
furnace firing. Also, in case of emergency bypassing is required to quickly cool down
the temperature of the reactor system. The temperature achieved by the feed
outlet of the exchangers is 321°C in SOR and 363°C in EOR.

2nd stage reactor feed furnace FF-002 is a twin cell heater having 24 burners in each
cell. The reactor feed (unconverted VGO + feed gas) is heated in radiation section
comprising of single pass located in the center of the firebox.

24
The second stage reactor is designed to operate at the inlet temperature ranging
from 343°C to 385°C at SOR to EOR condition. For obtaining better temperature
control the reactor is divided into 3 uneven beds which help to achieve the same
temperature rise in each bed and control the rise in temperature across the bed to
28°C. Internals are provided between each catalyst bed to ensure thorough mixing
with quench and to ensure the distribution of vapor and liquid flowing to each bed.
A thorough distribution of reactants is essential to prevent hotspots and to increase
catalyst life. The reactor operation is similar to that of lst stage reactor; it cracks
the VGO in the various components. And the place between the three beds is
quenched by the fuel gas to control temperature. The quenching is achieved by a
part of recycle gas from compressor KA-002.
The reactor effluent is cooled by incoming feed (liquid + feed gas) at 255/254°C to
the exchanger. The effluent is cooled upto 310/314°C (SOR/EOR). It further gets
reduced to 237/233°C by exchanging heat with atmospheric fractionator feed
which gets heated from 201/198°C to 255/258°C. The effluent is further cooled
down to 204°C by exchanging heat with BFW in EE-008. The separation of effluent
exchanger EE-008 at 204°C and 163.5Kg/cm2g into gas and liquid phase is done in
the Hot High-Pressure Separator VV-006.
Gas phase separated from liquid effluent contains mainly hydrogen. It still contains
a good amount of other hydrocarbons. Therefore, it is required to further cool it
for separation of these hydrocarbons to improve hydrogen purity in recycle gas.
The gases from VV-006 are passed through HXEE-009 where it exchanges heat with
feed gas (Recycle + make up H2). Gases further cool down to 65°C, in air cooler EA-
002A/B. The cooled gases at 65°C and 161.6Kg/cm2 are sent to VV-007 where
condensed vapor gets separated from gas phase. Gas phase is mostly H2 with small
amount of CH4, C2H6, C4H10, etc. which vary with SOR/EOR conditions. A demister
at the top section of the vessel removes any liquid entrainment in the gas before it
goes to the suction line of recycle hydrogen compressor KA-002.
The liquid from PT-002 comes to hot low-pressure separator VV-008 at 203°C and
36Kg/cm2. Here gases separated from the liquid are sent to the CLPSVV-009. The
recycle gas from VV-007 is circulated by steam driven centrifugal compressor.

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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.

26
 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.

 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.

27
 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.

28
 PROJECT REPORT

EFFICIENCY CALCULATION FOR RECIPROCATING COMPRESSOR

(MAKE-UP GAS COMPRESSOR)

Compressor

Compressor is a device which is used to increase the pressure of air from low
pressure to high pressure by using some external energy
• For filling the air in tube of vehicles
• In automobile service station to clean vehicles.
• For spray painting in paint industries.
• In vehicle to operate air brakes.
• For cleaning workshop machines.
• For supercharging of an IC engines.
• For operation of pneumatic tools i.e. rock drills, vibrators etc.

Make-up Gas Compressor

The primary gas to be compressed in refinery process units is hydrogen (H2). For
high-pressure hydrogen service [> 100 bar (1,500 psig)], such as hydrocracking,
reciprocating compressors are used for make-up gas service and
centrifugal compressors are typically employed for recycle gas service.

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 Classification of Compressor-

Compressor

Positive Continuous Flow

Displacement

Rotary Reciprocating Dynamic Ejector

Sliding Vane Mechanical Centrifugal/Radial

Piston

Liquid Piston Axial

Helical Mixed

Lobe

Screw
1

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Reciprocating Compressor

The primary components of a typical reciprocating compressor system can be seen

in Figures. The compression cylinders, also known as stages, of which a particular
design may have from one to six or more, provide confinement for the process gas
during compression. A piston is driven in a reciprocating action to compress the
gas. Arrangements may be of single or dual-acting design. (In the dual-acting
design, compression occurs on both sides of the piston during both the advancing
and retreating stroke.) Some dual-acting cylinders in high pressure applications will
have a piston rod on both sides of the piston to provide equal surface area and
balance loads.
Tandem cylinder arrangements help minimize dynamic loads by locating cylinders
in pairs, connected to a common crankshaft, so that the movements of the pistons
oppose each other. Gas pressure is sealed and wear of expensive components is
minimized through the use of disposable piston rings and rider bands respectively.
These are formed from comparatively soft metals relative to piston and
cylinder/liner metallurgy or materials such as polytetrafluoroethylene (PTFE).

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Reciprocating Compressor
In a reciprocating compressor, a volume of air is drawn into a cylinder, it is trapped,
and compressed by piston and then discharged into the discharge line. The cylinder
valves control the flow of air through the cylinder; these valves act as check valves.
Single – Acting compressor:
It is a compressor that has one discharge per revolution of crankshaft.
Double – Acting Compressor:
It is a compressor that completes two discharge strokes per revolutions of
crankshaft. Most heavy duty compressors are double acting.
Multi-staging :
Reduction in power required to drive the compressor.
Better mechanical balance of the whole unit and uniform torque.
Increase in volumetric efficiency.
Reduced leakage loss.
Less difficulty in lubrication due to low working temperature.
Lighter cylinders can be used.
Cheaper materials can be used for construction as the operating temperature is
lower.

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 OBERSVATIONS AND CALCULATIONS:

A polytropic process is a thermodynamic process that obeys the relation:

PVn=C……………………..(1)
where, P is the pressure, V is volume, n is the polytropic index, and C is constant.

From the control panel the following sets of reading were obtained for the
reciprocating compressor-
Stage A Stage B Stage C
Pressure P1(kg/cm2) 19.5 45 90
Temperature T1(K) 308 918 318
Pressure P2(kg/cm2) 46 91 178
Temperature T2(K) 411 406 398

We know that-
V=RT/P
Therefore equation (1) becomes-
P1V1n=P2V2n
P1(RT1/P1)n= P2(RT2/P2)n
Solving the above equation to determine the value of n for the following stages-
For stage A -
n1=1.5
For stage B-
n2=1.53
For stage C-
n3=1.49
Therefore, navg=1.51

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Workdone by reciprocating compressor for single stage :
W= (n/n-1) mRT1 [(P2/P1)n-1/n -1]…………………….(2)

Work done by multistage compressor :-

W = NS (n/n-1) mRT1 {(PNS+1/P1)(n-1/n)1/Ns -1}…………(3)
where, m = flow rate of hydrogen
Ns= number of stages
R = gas constant

Here, we have three stage compressor ,

Ns =3
n =1.51
m =25000 Nm3/hr
P1= 19.5 kg/cm2
P4 =178 kg/cm2
T1 =308 k
By putting above values in equation (3)
W = 7120402251 J/hr
= 1977889.574 J/sec
= 1977889.574 Watt

Theoretical Power consumption=3000000 Watt

Considering motor efficiency to be 80%
Power consumption = 3000000 * 0.8
= 2400000 W

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 power consumed by compressor
Efficiency of Compressor =
Power theoretically consumed
1977889.574
=
2400000
= 82.41%

35
 RESULTS
The efficiency of reciprocating compressor (Make Up Gas) was obtained as 82.41%.

CONCLUSION

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