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REPORT
INDIAN OIL CORPORATION LTD.
M ATHURA REFINERY
Submitted By:
SAGAR GUPTA
B.TECH, CHEMICAL ENGINEERING
JAIPUR
ACKNOWLEDGEMENT
It is great that Indian Oil Corporation Limited
provides training to a large number of students like us
for practical assimilation of knowledge pertaining to
our respective disciplines.
After the completion of the training program, I found it
to be of immense help, not only in supplementing the
theoretical knowledge, but also by gaining highly
practical knowledge regarding the actual work carried
out in a Refinery Plant.
TABLE OF CONTENTS
S.N
O
PROCESS UNIT
1)
2)
3)
REFINERY PROCESS
4)
4) a)
4) b)
4)c)
VBU(VISBREAKER UNIT)
4)d)
4)e)
4)f)
5)
PROJECT -1
MATERIAL BALANCE , WT. AND VOLUME YIELD OF AVU UNIT
Products
Auto
LPG
Turbin
Aviation
e
Fuel
(ATF
Bitumen
High Speed
Fuel
Industrial
Fuels
Liquefie
d
Petroleum Gas
Lubrica
nts
and
Services
I.O.C Refineries:
Digboi
Refinery,
Guwahati
Refinery,
Barauni
Refinery
Gujarat
Refinery
Haldia
Refinery
Mathura
Refinery
Panipat
Refinery
Bongaigon
Refining
Pipelines
Marketing
Training
Research
Developme
nt
&
Refinery
Greases
Marine Fuels
MS/Gasoline
Petrochemic
als
To work towards the achievement of selfsufficiency in the field of oil refining, by setting
MATHURA
REFINERY
1
0
take
care
environment.
of
1
2
CDU
PRESENT
FEED
CAPACITY(TM
TPA)
8000
1350
Bombay high
imported- high
sulfur
and low sulfur
crude
Vacuum gas oil ex-
OHCU
1200
CCRU
466
VBU
1000
DHDS
1100
DHDT
1800
Biturox
750
FCCU
PENEX(MS
Quality Up
440
gradation)
PRIME G+
(FCC
Gasoline
525
desulfurisatio
n)
Naphtha
Vacuum
residue(VR)
Straight run gas oil,
total cycle oil
Straight run gas oil
and total cycle oil
Vacuum residue
Naphtha, FCC
Gasoline
heart cut
FCC Gasoline
splitter
bottom
SPECIAL FEATURES
o MJPL:3.7 MMTPA
o Mathura tundia:1.2
MMTPA
o MBPL: 1MMTPA
Bit. Drum filling: by
Mktg
LPG bottling: by Mktg.
Crude Recipient thru
SMPL
Captive Power Plant
Mode of product
despatch
tank truck, tank
wagon
and pipeline
PRODUCTS:
Finished products from this refinery cover both fuel oil products as
well as lube oil base stocks.
13
Naphtha
Gasoline
Slack Wax
Carbon Black Feed
Stock
Bitumen
Sulfur
REFINERY PROCESS
The refining process depends on the chemical processes of
distillation (separating liquids by their different boiling points) and
catalysis (which speeds up reaction rates), and uses the principles
of chemical equilibria. Chemical equilibrium exists when the
reactants in a reaction are producing products, but those products
are being recombined again into reactants. By altering the
reaction conditions the amount of either products or reactants can
be increased.
PROCESS
UNIT
1
5
DESCRIPTION
1.1.
1.2.
TYPES OF CRUDE:
PRODUCTS OF AVU
LP
G
C5 - 120 C cut
Naphtha Component
C5 - 118 C cut
12 - 135 C cut
0 (BH)
11 - 142 C cut
8 (AM)
13 C cut
5 255 (BH)
14 C cut
2 255 (AM)
25 C cut
5 296 (BH)
25 C cut
5 300 (AM)
(AM)
325 - 380 C cut (LS)
HVGO component
HSD component
(<380 C cut )
380 - 425 C cut
SR
Hydrocarbon Gas
the
tank
and
is
pumped
through
series
of
heat
1
9
under
reduced
pressure
takes
place.
Different
off-sites are used to deliver crude to the unit feed pumps. Filters
are installed on the suction manifold of crude pumps to trap
foreign matter. For processing slop, pumps are located in the offsite area, which regulate the quantity of slop into the crude header
after
filters.
Provision
to
inject
proportionate
quantity
of
demulsifier into the unit crude pumps suction header with the help
of dosing pump is available.
2
1
field in the desalter breaks the emulsion and the outlet brine
from the 1st stage desalter is sent to ETP on level control.
1.7.
FURNACE OPERATION:
2
2
The furnaces are of balanced draft type with forced draft (FD) fans
to supply combustion air and induced draft (ID) fan to take
suction of the flue gases through air-preheating system and
discharge the same to stack.
2
3
2
4
The vaporized portions entering the flash zone of the column along
with stripped light ends from the bottoms rise up in the vacuum
column and is fractionated into four side stream products in 5
packed sections. The hydrocarbon vapors are condensed in the
Vac Slop, HVGO, LDO and LVGO sections by circulating refluxes to
yield the side draw products. Vacuum is maintained by a two-stage
ejector system with surface condensers. The condensed portion
from the condensers are routed to the hot well from where the
non-condensable are sent to the vacuum furnace low-pressure
burners or vented to the atmosphere.
2
5
2
6
In this process Heavy Gas Oil cut (Raw Oil) from Vacuum
Distillation Section of AVU is catalytically cracked to obtain more
valuable light and middle distillates. The present processing
capacity of the unit is about 1.48 MMT/Yr. It consists of the
following sections:
Catalytic section,
2
7
2
8
the standpipe flows into the riser through a slide valve to complete
the catalyst circulation cycle. Catalyst particles in the flue gas
leaving the regenerator are separated at the top of regenerator by
three sets of two-stage cyclones. The flue gas contains both CO
and CO2 as carbon is burnt off partly to CO and partly to CO2 in
the regenerator. The sensible and chemical heat in flue gas is
utilized to generate steam in CO Boiler. The flue gas is passed
through' the orifice chamber & regenerator. Pressure is controlled
by double disc slide valve. Orifice chamber holds backpressure
downstream of double-disc slide valve. By reducing the pr. drop
across slide valve, operating life of slide valve is greatly extended
by avoiding sudden accelerations of catalyst, bearing flue gas
stream. The unit is designed for use of high ZEOLITE catalyst
(Fresh catalyst), which is microspheriadical in shape.
pass
fractionator.
overhead
through
the
vapour
line
into
the
3
0
Equilibrium catalyst
3
1
In this section, the vapors coming out of the reactor top at very
high temperature are fractionated into wet gas and un-stabilized
gasoline overhead products, heavy naphtha, and light cycle oil as
side products. Heavy cycle oil drawn from the column is totally
recycled along with the feed after providing for the recycle stream
to the column.
The column bottom slurry containing a small quantity of catalyst is
sent to a slurry settler. From the settler bottom, the thickened
slurry is recycled back to the riser for recovering catalyst is sent to
a settler and from the settler bottom, the thickened slurry is
recycled back to the riser for recovering catalyst and further
32
cracking. From the top of slurry settler, clarified oil product is taken
out after cooling which goes for blending in Fuel Oil.
Heavy naphtha and light cycle oil streams after steam stripping
are used as gas oil blending components. The un-stabilized
gasoline and wet gas are sent to Gas Concentration Unit for
further processing. Both heavy naphtha and light cycle oil being
blending components for HSD can be blended in the unit and sent
to product blending station, as a single stream. In addition, light
cycle oil, if required for blending in FO, fertilizer feed, etc. can be
diverted to the extent required for
product
blending
in
separate
line.
3
3
The
wet
gas
from
the
fractionator
overhead
receiver
is
2.6. CO BOILER
The flue gas leaving the regenerator via orifice chamber contains
8-13% carbon monoxide, the rest being inert like nitrogen, steam,
carbon dioxide, etc. In the CO Boiler, flue gas is burnt with air
converting, carbon monoxide to carbon dioxide, thus releasing the
heat of combustion of CO in the boiler. This heat as well as the
sensible heat in flue gas available at a high temperature is utilized
for raising medium pressure steam.
3
4
VIS-BREAKING
UNIT
3.1. Introduction:
The Visbreaker Unit is
designed for
processing a mixture
of Atmospheric and
Vacuum Residue from
1:1 mixture of Light
Arabian and North
Rumaila Crudes. It
reduces the viscosity
and pour point of
heavy petroleum
fractions so that
product can be sold as
fuel oil. The nominal
capacity of the plant is
0.8 MMTPA of mixed
Feed Stream
Atmospheric
Residue
Vacuum Residue
Design
Capacity,MMTPA
400
600
3
6
remain at high temperature and soak heat for some time. Severity
of
over-all
reaction
is
determined
by
residence
time
and
of
visbreaking
reaction.
The
soaker
effluent
is
steam
Thermocouples
coils,
and
flue
gas
are
also
provided
to
inside
stack
temperatures.
furnace
tubes
for
26 valve trays and one blind tray. Feed enters flash zone below the
26th Valve tray.The overhead vapours from the column are
condensed and cooled in heat exchangers.
3
9
4
0
o
o
Tar is cooled from 351 C to 225 C in feed exchangers and further
o
cooling to 214 C is done. Pumps are having two filters in the
suction line with gas oil flushing facilities. Only one filter is kept in
service while the other remains as spare. Cooled VB tar is partly
used as quench to
3.6. Stabilizer
Un-stabilized gasoline from reflux drum is picked up by reflux
pump and then it is pumped to stabilizer through stabilized
o
gasoline exchanger. In heat exchanger, feed is heated from 43 C
o
o
to 120 C while stabilized gasoline is cooled from 180 C to 120
o
C. The column has 30 trays and the feed enters on the 19th.The
o
overhead product at 60 C goes to water condensers. The
condensed liquid is collected in the reflux drum. Uncondensed gas
from the drum goes to FCC/unit fuel gas header. Pressure at the
2
drum is maintained at 8.4kg/cm (g).
regeneration
of
catalyst
unlike
in
earlier
semi-
naphtha
through
catalytic
reforming
process.
Reformate
so
95/5 blend of naphtha from Arab mix (80-1450C TBP
cut) and vis-broken Naphtha (Feed II)
4
2
Composition: - wt.
%
Feed
Feed I
Feed II
PARAFFIN
iC5
0.20
0.00
nC5
0.3
0.04
iC6
3.80
4.29
nC6
4.98
5.61
C7
20.76
9.88
C9
5.88
5.55
C10+
0.89
0.27
N5
0.26
0.24
N6
7.97
8.91
N7
13.33
13.07
N8
3.81
7.78
N9
2.39
2.55
N10
0.00
0.00
A6
6.87
8.14
A7
7.85
12.38
A8
4.21
11.39
A9
0.32
0.07
A10
0.00
0.00
NAPHTHENE
AROMATIC
TOTAL
100.00
100.
00
43
Catalytic
Reforming
is
major
conversion
process
having
LPG
CCRU
4
4
O
stabilizer section at a temperature of about 60
C. This
naphtha is pre-heated by column bottom Heavy naphtha in
feed-bottom exchanger to 95 C
In case of pre-planned AVU shutdown, stabilized naphtha (C5150 oC) will be stored in the existing naphtha tanks and
processed in NSU as cold feed.
b) SPLITTER SECTION:
Naphtha splitter receives feed on its 19th tray. The hot feed
from AVU/cold feed, after getting preheated goes to the LP
steam pre-heat exchanger, and the MP steam pre-heat
exchanger, before entering the splitter. In former,
0
the naphtha feed temperature is increased to 135 C from 95
0
C by LP Steam and in later the required feed temperature of
0
145 C is achieved by using MP Steam. The feed naphtha
after preheating enters the splitter through the control valve.
Splitter has a total of 40 trays.
Splitter re-boiler supplies the heat necessary for splitter reboiling. It is a six pass vertical cylindrical heater with 6
burners having provision for
4
6
combination firing of both fuel gas and fuel oil. However they
are designed for 100 % of fuel gas or fuel oil firing.
Desired
the fuel
with 12
studded
o
tube skin temperature for the heater is 253 C.
head.The
total
condensate
received
in
the
4
7
(nickel,
molybdenum)
and
optimum
operating
4
8
4
9
inlet & one outlet nozzle for feed & effluent respectively. Catalyst
enters the reactor through 12 nos. of 3" pipes, flows through the
space between external grid and the central pipe from top to
bottom and exits through 12 nos. of 2"pipes, slow moving bed of
bimetallic catalyst and exits through the outlet nozzle at the
bottom. The radial flow of feed is achieved by directing the flow
through external grid to catalyst bed & exit is made to central
outlet collector pipe. Gas tight baffle is provided on the outlet pipe
to avoid short-circuiting of the feed to outlet pipe
o
C and then by trim cooler
o
to 45 C before entering the separator. The separated gas is
3.7.
Process Licensor:
IFP, France
LSTK Contractor:
Daelim, S. Korea
PMC:
Capacity:
Turndown:
50%
IFP Licensed Hydro treating
technology
Process:
Capacity Basis:
8000 HRS/YEAR
Cost:
6000 crores
Commissioning date:02/05/2005
PURPOSE OF
3.8. UNIT:
To reduce low sulfur (<30ppm) and high cetane number (55)
HSD to cater to
the needs of bharat stage II, bharat stage III and bharat stage
IV.
With recommendation of task force of governments AUTO
FUEL POLICY, following emissions norms will be followed.
3.9.
BHARAT STAGE I
2500 ppm
BHARAT STAGE II
500 ppm
350 ppm
BHARAT STAGE IV
50 ppm
51(min)
52
Treating reactions:
Metal removal
Olefin saturation
Sulfur removal
Nitrogen removal
Oxygen removal
Desulfurisation reactions:
The aliphatic sulfur compounds, namely mercaptants, sulphides
and di-sulphides react easily leading to the corresponding
saturated or aromatic compounds. Thiophenes sulfur is most
difficult to react. The reaction is exothermic.
Mechanism:
Sulfur removed first, and then the olefin is saturated. Three mole
of hydrogen consumed per mole of sulfur. 560 kcal of heat
3
liberated per Nm of H2 consumed.
Mercaptant
R-SH + H2
Sulphides
R-S-R + 2H2
RH +
H2S
2RH +
H2S
DENITROFICATION REACTIONS:
These
reactions
lead
to
ammonia
formation
and
are
Mechanism:
First saturation of the rings to which nitrogen is attached and then
carbon nitrogen bond scission. Five mole of hydrogen consumed
for per mole of nitrogen. 632 to 705 Kcal of heat liberated per Nm3
of hydrogen consumed.
5
4
Amine
CH3-CH2-CH2-CH2-CH2-NH2 +H2
CH3 + NH3
CH3-CH2-CH2-CH2-
RICH AMINE
ARU
ACID GAS
LEAN AMINE
STEAM VENT
MP STEAM
SRU
L P STEAM
LP STEAM
SOUR WATER
STRIPPED WATER
SULPHUR
TGTU
SWSU
SOUR GAS
55
This unit is basically low pressure (slightly above then atm) unit
having throughput of 60 tons/day.
The Sulfur Recovery Unit is designed to recover sulfur from
the sour vapors originating from the following sources:
1) The Amine Regenerator Unit
2) The Sour Water Stripper Unit
Feed Specifications
The feedstock of the SRU is a mixture of the Acid gas ex ARU
and the Acid gas ex SWS, 50% of the feed to the SRU is to be
processed in the two of the three
trains.The quantity and quality of H2S feed to the unit will vary
depending on the shutdown of the various preceding units. The
unit should be capable of converting 99% wt. of the H 2S
contained in the feed streams to sulfur in all the following cases:
Case 1: When all units are running with HCU on 70% IMP HVGO.
2.2
2.2
H2S
4805.0
560.7
5365.7
H/S*
11.3
11.3
CO2
338.3
338.3
137.0
137.0
309.9
432.6
1007.6
6287.1
NH3
H2O
122.7
56
Total feed
H2
0.3
0.3
H2S
1727.2
545.9
2273.1
H/S*
11.3
11.3
CO2
338.3
338.3
218.3
218.3
364.8
412.9
1129.0
6287.1
NH3
H2O
48.1
Gas ex-SWS
Gas ex-ARU
o
Temperature, C
90
40
2
Pressure, kg/cm g
0.7
0.7
57
Capacity
The unit consists of three parallel SRU trains, each with a
sulfur production capacity of 60 metric tons/day, a tail gas
incinerator and a sulfur degassing
system. Two SRU trains are normally in operation and one SRU
train is in the hot stand-by mode.
Sulfur Recovery Rate
State
Color
Purity
liquid sulfur
bright yellow (as solid
state)
min. 99.9 wt% on dry
basis
H2S
58
3S + 2H2O + Heat
The process gas leaving the waste heat boiler still contains a
considerable part of H2S and SO2. Therefore, the essential
function of the following equipment is to shift the equilibrium by
adopting a low reactor temperature thus removing the sulfur as
soon as it is formed.
Conversion to sulfur is reached by a catalytic process in two
subsequent reactors containing a special synthetic alumina
catalyst.
Before entering the first reactor, the process gas flow is heated to
an optimum temperature by means of a line burner, with mixing
chamber, in order to achieve a high conversion. In the line burner
mixing chamber the process gas is mixed with the hot flue gas
obtained by burning fuel gas with air.
In the first reactor the reaction between the H2S and SO2
recommences until equilibrium is reached. The effluent gas from
the first reactor passes to the first sulfur condenser where at this
stage approximately 29% of the sulfur present in the sour gas feed
is condensed and drained to the sulfur pit. The total sulfur
recovery after the first reactor stage is 89% of the sulfur present in
the sour gas
5
9
6
0
PROJECTI
61
Feed
3
Flow rate (m /hr)
1147
Density (Kg/ )
0.855
LPG(STABILIZER)
29
0.515
LIGHT
NAPTHA(STABILIZER)
ATF
181
0.720
111
0.787
HY KERO
46
0.819
HEAVY NAPTHA
21
0.762
LGO
212
0.845
HGO
45
0.875
LVGO
11
0.882
LDO
21
0.897
HVGO
175
0.929
SR
285
0.999
62
PRODUCT
On Wt. basis
On Volume basis
1
.
LPG
0.0152
0.0255
LIGHT NAPTHA
0.13289
0.15919
ATF
0.0891
0.0976
4 HY KERO
0.0384
0.04045
5 HEAVY NAPTHA
0.0163
0.01846
6 LGO
0.1826
0.18645
7 HGO
0.0401
0.03957
8 LVGO
0.00989
0.00967
63
LDO
10 HVGO
11
SR
0.0192
0.01847
0.1657
0.15391
0.290
0.25065
64
Submitted By:
SAGAR GUPTA
B.TECH, CHEMICAL ENGINEERING
MNIT, JAIPUR
65