VOCATIONAL TRAINING REPORT

I.O.C.L HALDIA REFINARY

Period of Training : 19th May, 2017 to 17th June, 2017

Submitted by : Aditya Chaudhury

Anubhab Das

Rajat Srivastava

JADAVPUR UNIVERSITY
DEPARTMENT OF CHEMICAL ENGINEERING

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 Acknowledgement

This report wouldn’t have been possible without the constant help and guidance of a few
individuals whose support has been vital to the completion of the report.

We extend our sincere thanks to Indian Oil Corporation Limited for giving us this
wonderful opportunity to do summer internship.

We wish to express our gratitude to our supervisors, in all the units that we visited, who
has been abundantly helpful and offered invaluable assistance, support and guidance.
Some of the few names are:-

1. Mr. S. Kumar,PNM (F.O.B.)

2. Mr. C. Sahoo,PNM(L.O.B.)

3. Mr. P. Adhikary,SPNM (D.H.D.S.)

4. Mr. K. C. Nayek,PNM(E.T.P)

5. Mr. D. P. Chakraborty,SPNM(O.M.&S.)

6. Mr. U. K. Jana,DMPN(B.F.S)

7. Mr. J. Banarjee,SPNM(O.H.C.U)

Special thanks to all my group members for sharing the hardwork in making this report.

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 INDEX

SERIAL NO. DESCRIPTION

1 INTRODUCTION
2 PROFILE OF HALDIA REFINERY
3 FUEL OIL BLOCK
4 LUBE OIL BLOCK
5 DIESEL HYDRO-DESULPHURISATION UNIT
6 ONCE THROUGH HYDROCRACKING UNIT
7 Oil Management And Storage
8 Bitumen Filling Station
9 Effluent Treatment Plant
10 Conclusion

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 Introduction
This report contains a brief study on the following units which we visited in summer 2017
for 30 days vocational training programme at IOCL Haldia. The units are:-

1. Fuel Oil Block

2. Lube Oil Block

3. Diesel Hydo-DeSulphurisation Unit

4. Once Through HydroCracking Unit

5. Liquefied Petroleum Gas

6. Effluent Treatment Plant

7. Oil Management And Storage

8. Bitumen Filling Station

The study based project has been completed using the data provided to us by the
respective supervising officers in each of the units and the data found in the internet. The
objectives of the study are:-

 To get an exposure of the actual working environment within a multi-national.

 To thoroughly understand the process dynamics of all the units inside the control
panels.
 To understand the benefits of coastal location of the refinery.
 To see the different machines and how it works.

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 PROFILE OF HALDIA REFINERY
Haldia Refinery, one of the eight operating refineries of IndianOil, was commissioned in
January 1975. It is situated 136 km downstream of Kolkata in the district of Purba
Medinipur, West Bengal, near the confluence of river Hoogly and Haldia.

Indian Oil Corporation Ltd. (IOC) is the flagship national oil Company in the downstream
sector. The Indian oil group of companies owns and operates 10 of India’s 19 refineries
with a combined refining capacity of 1.2 million barrels per day. These include two
refineries of subsidiary Chennai Petroleum Corporation Ltd . (CPCL) and one of the
Bongaigaon Refinery and petrochemicals Limited (BRPL). The various refineries are :

 Guwahati Refinery
 Barauni Refinery
 Gujarat Refinery
 Haldia Refinery
 Mathura Refinery
 Digboi Refinery
 Panipat Refinery
 Paradip Refinery
 Bongaigaon Refinery

From an original crude oil processing capacity of 2.5 MMTPA, the refinery is now operating
at a capacity of 7.5 MMTPA at present. Capacity of the refinery was increased to 2.75
MMTPA through de-bottlenecking in 1989-90, and to 3.75 MMTPA in 1997 with the
installation/commissioning of the second Crude Distillation Unit of 1.0 MMTPA capacity.
Petroleum products from this refinery are supplied mainly to eastern India through two
product pipelines as well as through barges, tank wagons and tank trucks. Products like
MS, HSD and Bitumen are exported from this refinery.

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Haldia Refinery is currently the only coastal refinery of the corporation and the
lone lube flagship, apart from being the sole producer of Jute Batching Oil. Diesel Hydro
Desulphurisation (DHDS) Unit was commissioned in 1999, for production of low Sulphur
content (0.25% wt) High Speed Diesel (HSD). With augmentation of this unit, the refinery is
producing BS-II and Euro-III equivalent HSD (part quantity) at present. Resid Fluidised
Catalytic Cracking Unit (RFCCU) was commissioned in 2001 in order to increase the
distillate yield of the refinery as well as to meet the growing demand of LPG, MS and HSD.
Refinery also produces eco friendly Bitumen emulsion and Microcrystalline Wax. A
Catalytic Dewaxing Unit (CIDWU) was installed and commissioned in the year 2003 for
production of high quality Lube Oil Base Stocks (LOBS), meeting the API Gr-II standard of
LOBS. In order to meet the Euro-III fuel quality standards, the MS Quality Improvement
Project has been commissioned in 2005 for production of Euro-III equivalent MS. The
refinery expansion to 7.5 MMTPA as well as a Hydrocracker project has been approved,
commissioning of which shall enable Haldia Refinery to supply Euro-IV and Euro – III HSD
to the eastern region of India.

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 Basic Refinery Processes

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 Block Flow Diagram of Haldia Refinery

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 Fuel Oil Block

FOB

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 Fuel Oil Block (FOB)
Fuel oil block is the unit that takes imported crude oil from storage and performs initial
separation of broad components in an atmospheric distillation column. The broad
components are further modified to other products which are treated, stored and finally
marketed.

The main sectors of this unit are as follows-

1. Crude Distillation Unit

 Prefractionator column
 Atmospheric Distillation unit
 Naphtha stabilisation unit
 Naphtha re-distillation unit
2. Naphtha hydrotreating unit
3. Catalytic reforming unit
4. Kero hydro-desulphurisation unit

Crude Distillation Unit

Distillation is the separation of feed mixture (crude oil) into fractions by selective boiling
and condensation. Multi-component distillation gives more than two output streams-top,
bottom and side streams. The top product contains low boiling hydrocarbons while the
bottom product consists of reduced crude oil sent for further processing to VDU. The side
streams are separated on basis of their relative volatility.

The crude oil is distilled under atmospheric pressure for producing multi-component
distillates and sent to OMS. Crude oil from various off-site sources serve as the feed.

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Product streams :

 LPG (overhead)
 Naphtha
 Kerosene/ ATF
 Diesel
 Jute Batching Oil (JBO)
 Reduced Crude Oil (RCO)- (bottom)

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Crude oil is heated to 120 0C in a set of pre-heat exchangers and fed to desalter. Calcium
and Magnesium salts present in the crude is desalted to 95 % in the desalter. Crude
temperature is raised to 200 0C in a second set of heat exchangers and pretopped in a
prefractionator column.

 Overhead product is gasoline.

 Bottom product is pre-topped crude.

Crude is further pre-heated to 260 0C and finally to 350 0C in a furnace. Prefractionator

reduces the load of the main distillation column.

Crude oil is then fractionated in the atmospheric distillation column to obtain multi-
component product streams.

 Overhead product contains very low boiling hydrocarbons upto butane and is
fractionated in a stabilisation column.
 Stabiliser overhead- It contains upto C5 cut and is fed to de-ethaniser and de-
propaniser for the separation of ethane, propane and butane.
 Stabiliser bottom- C5-140 cut is obtained from the stabiliser bottom and
routed to naphtha re-distillation column. Here it is further splitted into light
and heavy naphtha and the latter is used as feedstock for catalytic reforming
unit.

Naphtha Hydro-treating Unit

This unit prepares the heavy straight run naphtha for catalytic reforming by the
elimination of sulphur. Sulphur causes corrosion, coking, deactivation of catalysts and
many environmental issues.

Heavy straight run naphtha is heated to 300 0C in a furnace. Pre-heat exchangers are used
to reduce the load of the furnace. The feed is then introduced to de-sulphurisation reactor
where Ni-Mo oxides on alumina are used as catalyst. Hydrogenation occurs leading to
formation of H2S which is stripped out. Hydrotreated naphtha is sent to catalytic reforming
unit.

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Catalytic Reforming Unit
Catalytic reforming increases the octane number of naphtha. Octane number is the % of
iso-octane in a mixture of iso-octane and n-heptane which possesses same knock
performance as the fuel under test. The more the octane number, the more is the
knocking tendency in the engine. Aromatics help reduce knocking while straight chained
paraffins have highest knocking tendency.

The hydro-treated naphtha is heated and completely vaporised in a furnace. It enters a

reactor filled with platinum catalyst where catalytic reforming reactions like
dehydrogenation, isomerisation and cracking take place. There are three reactors for the
same purpose. Feed has to be re-heated before being passed to the subsequent reactor as
reforming reactions are endothermic in nature. The final product is reformed naphtha
which is sent to Motor Sprit Quality Upgradation unit.

Kero Hydro De-Sulphurisation Unit (KHDS)

This unit removes sulphur from kerosene distillate cut produced from atmospheric
distillation unit.

Kerosene/ ATF is heated to reaction temperature in a furnace and set of pre-heat

exchangers. The feed is flown into a de-sulphurisation reactor filled with Co-Mo catalyst.
The sulphur is converted to H2S which is stripped off by amine wash.

The final product is treated kerosene/ATF which is less corroding in nature.

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 Lube Oil Block

LOB

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 Lube Oil Block

The major properties of any lube are :

1. Kinematic viscosity : It is resistance to flow of a liquid offered by the individual

layers of the liquid itself. It should be less to allow easy flow of the lube.
2. Viscosity index : It defines the rate of change of kinematic viscosity with
temperature. Since changing of viscosity with temperature is undesirable, viscosity
index should be lowered.
3. Flash Point : It is the highest application temperature at which oil would work
without getting deteriorated. This is an indication of vaporisation loss. The flash
point of lubes must be low so that lubes do not freeze in cold countries.
4. Pour Point : It is the lowest temperature at which oil would maintain its fluidity that
is remain in liquid state. It should also be low.
5. Colour : Lube oil base stock should be watery in appearance. The colour that we see
in most of the marketed lube oils iis due to the additives added to them.
Degradation of colour marks the degradation of the lube base.
6. Oxidation stability : Oxidation stability is required so as to reduce any chances of
polymerisation when in contact with oxygen. This happens due to presence of
unsaturates.

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 Vacuum Distillation Unit (VDU)
Its main purpose is to distil the Reduced Crude Oil obtained from Atmospheric Distillation
Column, under vacuum for preparing feed of Lube Oil.

 Feed : Reduced Crude Oil (RCO)

 Products : Gas oil/Diesel
Spindle Oil
Light Oil
Inter Oil
Heavy Oil
Vacuum Residue or Short Residue

Reduced crude is preheated in a series of heat exchangers (pre-heat exchanger train) by

exchanging heat with the high temperature product streams and then passed through two
oil fired furnaces to achieve a temperature of around 400 0 C. This heated stream is flashed
in the vacuum distillation column operating at 70 mm Hg (below atmospheric pressure).

Products like SO, LO, IO and HO are drawn off from the column as side streams. Each
product is stripped in their respective stripper columns to remove the lighter components
and increase flash points. Vacuum residue is drawn from the bottom of the column.

As the boiling points reduce with decrease in pressure, RCO need not be raised to a very
high temperature for further distillation. High temperatures lead to coke formation in
pipelines, columns and vessels blocking/clogging them hence restricting further flow which
is undesired.

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 Propane De-Asphalting Unit
The main aim of this unit is to recover the valuable oil left in the Vacuum Residue. This is
called “bottom of the barrel” processing. The recovered oil called De-Asphalted Oil (DAO)
serves as feed for lube oil making.

 Feed : Vacuum Residue

 Products : De-Asphalted Oil
Asphalt

DAO is recovered by means of extraction process with liquid propane as solvent. Propane
dissolves the oil and rejects the asphalt. Counter-current mass transfer takes place inside
the extractor. Propane dissolves the oil part and comes out from top as the DAO mix while
asphalt being heavy is withdrawn from the bottom as asphalt mix. Propane is recovered
from both the DAO mix and Asphalt mix and re-circulated.
Residual Oil Super Critical Extraction (ROSE) technology is used to recover propane from
the DAO mix where the DAO mix is taken to its critical temperature and pressure
conditions.

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 Furfural Extraction Unit (FEU)
This unit removes the aromatic hydrocarbons from the Vacuum Distillates (SO,IO,HO and
DAO) for improving the viscosity index of the products.

 Feed : Vacuum distillates

 Products : Raffinates of SO, LO, HO and DAO
Extracts of SO, LO, HO and DAO

The separation process used is extraction and the solvent used is furfural. Furfural has high
affinity for aromatics and dissolves them, thereby creating two phases- Raffinate (lean in
aromatics) and Extract (rich in aromatics). Solvent is recovered from both the streams and
recirculated back after proper drying.

Hydro-Finishing Unit (HFU)

This unit aims at improving the colour and colour stability of Lube Base Stocks.
 Feed : De-waxed oils from SDU
 Product : Finished lube

The process is a mild hydrotreating one, using a catalyst in presence of hydrogen at high
temperature and pressure. The process removes contaminants like sulphur, nitrogen and
unsaturates.
At high hydrogen partial pressure and in presence of catalyst, Sulphur and Nitrogen in the
feed gets converted to Hydrogen Sulphide and Ammonia respectively. The unsaturates are
saturated to stable products.

The feed mixed with hydrogen and after being heated in a series of pre-heat exchangers
and furnace is fed to the hydro-finishing reactor. The reactor outlet is cooled and vapours
are removed. The remaining liquid is stripped off lighter components and sent to storage.

This process gives lubes of various grades as the finished products.

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 Visbreaking Unit

Here the high viscosity feed stock like asphalt are converted to low viscosity products like
tar or furnace oil which can be put to various other uses in the refinery.

 Feed: Vacuum residue, asphalt and other heavy extracts

 Products: Gas oil, gasoline and fuel gas

Vis-breaking is a mild thermal cracking process where long chained hydrocarbon molecules
in heavy feed stocks are broken into small molecules having low viscosity. The feed stock is
heated to a relatively low temperature of 450 0 C in a furnace and then held in a soaker
drum for longer residence time (30 minutes) to achieve the required conversion. The
soaker outlet is fractionated in a column to obtain on-spec furnace oil or tar.

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 Catalytic Iso Dewaxing Unit (CIDWU)
This unit aims at producing superior grade lubes of group 2 by conversion of wax
component in raffinate feed to non-waxy components by the process of isomerisation of n-
paraffins to iso-paraffins.

 Feed : Raffinates of SO, LO, IO, HO and DAO

 Product : Dewaxed oils of SO, LO, IO, HO and DAO

The feed is purified in Hydro-treatment reactor at an elevated temperature. The

sweetened feed is stripped off Hydrogen sulphide and ammonia in a stripper with pure
hydrogen gas. Then it is fed to a dewaxing reactor. The liquid part of reactor outlet is
fractionated to remove lighter components for achieving desired specifications. This unit is
better than SDU because of its increased yield and greater superiority of lubes.

Fig.- Catalytic Iso De-Waxing Unit

The final product is Lube Base stock of certain specification which is sent to Indian Oil
Blending Limited (IOBL).

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 Diesel Hydro Desulphurisation
Unit
DHDS

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 Diesel Hydro Desulphurisation Unit (DHDS)
The Diesel Hydro De-sulphurisation Unit is based on uniofining process, designed to
process distilled oil. Petroleum fractions contain various naturally occurring contaminants
like sulphur, nitrogen and metal compounds which leads to corrosion, pollution and causes
difficulty in further processing the material. The unionfining process is a fixed bed catalytic
process for hydrotreating feed stocks.The process uses catalytic hydrogenation to upgrade
the quality of petroleum distillate fractions by decomposing contaminants. Unionfining is
designed primarily to remove sulphur and nitrogen.Unionfining catalysts are composed of
Nickel or Cobalt with Molybdenum oxides on a alumina base.

Sulphur Removal :
Feed stocks containing mercaptan, sulphide and disulphide are easily converted to H2S.
This H2S is absorbed in amine which becomes rich amine and sweeten the feed stock. H2S
is further stripped off the rich amine in a Amine Recovery section and converted to
sulphur.

Nitrogen removal :
Denitrogenation is more difficult than desulphurisation. Feed stocks are hydrogenated and
formation of NH3 occurs. This NH3 is stripped off from the feed stock.

Oxygen removal :
Organically combined oxygen is removed by hydrogenation of carboxyl bond forming water
and corresponding hydrocarbon.
Phenol + H2 = Benzene + H2O

Olefin saturation :
Olefin saturation reacton proceeds very rapidly and have high heat of reaction.

Aromatic saturation :
These reactions are most difficult and are very exothermic.
Benzene + H2 = Cyclohexane

The DHDS block consists of the following units:

1. Motor Sprit Quality Upgradation Unit
2. Resid Fluidised Catalytic Cracking Unit
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 3. Vacuum Distillation Column
4. Diesel Hydro De-sulphurisation Unit
5. Nitrogen plant
6. Air plant
7. Amine regeneration unit
8. Sour water stripper
9. Sulphur recovery unit

Diesel Hydro De-Sulphurisation Unit

The process involves hydrogenation of sulphur and nitrogen compounds that are present in
diesel and decomposing the contaminants to upgrade quality of diesel. Hydrogenation
results in the formation of H2S which is absorbed into a countercurrent flow of amine. The
rich amine is sent to amine recovery unit for regeneration of lean amine. The process also
saturates the olefins and aromatic compounds present in diesel.
Following are the chemical reactions taking place other than sulphur removal, in hydro de-
sulphurisation process :
1. Nitrogen removal- Denitrogenation is a very difficult process and occurs
during hydro-treating.
2. Oxygen removal- Organically combined oxygen is removed by
hydrogenation of the carboxyl bond, forming water and corresponding
hydrocarbon.
3. Olefin saturation- The linear and cyclic olefins are converted to straight
chain molecules after hydrogenation.
4. Aromatic Saturation- Aromatic saturation is most difficult among all
reactions mentioned just above.
5. Other side reactions- These involve metal removal, hydro-cracking
reactions etc.

Amine Recovery Unit

There are three amine regeneration units in the DHDS block. They cater to the needs of
RFCCU, DHDS, FOB, LOB and OHCU units. The rich amine from various amine absorbers is
stripped off H2S by using medium pressure steam in a regeneration column. The lean
amine obtained from the bottom of regeneration column is cooled and recycled back to
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amine absorbers. Absorbent used is di-ethanol amine.

Sulphur Recovery Unit

Claus Section

The main reaction occurring in the burner is

H2S + 1.5 O2 ----> SO2 + H2O + heat

A major part of the residual H2S combines with SO2 to form sulphur according to the
reaction

H2S + SO2 -----> 1.5 S + 2H20 – heat

This is called Claus reaction.

The waste heat boiler remove major portion of the heat generated in the burner and
utilise it to produce steam. The process gas from the waste heat boiler enters a sulphur
condenser where the formed sulphur is removed from the gas. The process gas leaving
sulphur condenser still contains considerable amount of H2S and SO2. The process gas is
passed through 3 more reactor stages to convert H2S and SO2 to sulphur but this time at
lower temperatures. Each reactor stage is followed by a sulphur condenser where sulphur
is condensed and the remaining process gas is passed onto the subsequent reactor stage.
In the Super-Claus stage, the remaining H2S is selectively oxidised to sulphur.

2H2S + SO2 (3/8) S8 + 2H2O + heat

The tail gases are sent to reduction tower where the unconverted SO2 is converted to H2S.
The gas is then sent to amine absorber where H2S is removed. The tail gases are then
incinerated .

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ONCE THROUGH HYDRO CRACKER
UNIT

OHCU

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In OHCU , Hydrogen is the most important compound. It is used for hydro cracking, hydro
treating and also acts as a carrier.

If H2 is deficient, coking may take place.

Desired method of coking is catalytic cracking but thermal cracking is undesired so it must
be prevented because it may lead to high heat generation and temperature runaway may
result to failure of metals. In such case depressurization may be implemented to control
the situation.

Two steps are implemented:

 Hydrotreating
 Hydrocracking
FEED TO OHCU:

The feed of OHCU comes from VDU(Vacuum Distillation Unit) which is called
VGO(Vacuum Gas Oil).

VGO consists of spindle oil, light oil, intermediate oil.

The nature of the oil is thick and viscous.

HGU
Hydro-cracking is a costly process yet it is done to remove sulphur components. Sulphur
causes high corrosion in the engines and has to be removed. The following processes occur
in the unit:

1. FEED PRE-DESULPHURISATION:

The feed contains unsaturated components as well as high amount of organic sulphur.
Sulphur would act as a poison for the downstream processes and needs to be removed.
The bulk of the sulphur can be removed by conversion (Hydrogenation) of the organic
sulphur components to H2S and subsequent stripping. As an important side reaction
Olefins are saturated. The Basic reactions occurring in the section are as follows:
RSH + H2 RH + H2S
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RCL + H2 RH + HCL
R=R + H2 R-R

2. FEED DESULPHURISATION :

Sulphur and Chloride poison the pre-reforming and reforming catalyst in the hydrogen unit
even at very low levels. These catalyst poisons can be effectively removed in the form of
H2S and HCl by selective adsorbents (Zinc Oxide and Aluminium Oxide respectively). The
reactions involved are:

Co-Mo Catalyst:
RSH + H2  RH + H2S
Chlorine Guard:
AL2O3 + 6HCL  2ALCL3 + 3H2O
Zinc Oxide Catalyst:
ZnO + H2S  ZnS + H2O

3. PREREFORMING AND REFORMING:

The feed in the presence of steam reacts to a mixture of methane, carbon dioxide, carbon
mono oxide and hydrogen over a nickel based catalyst. These reactions take place in both
the pre-reformer and the reformer. The principal reactions are:

CnHm + nH2O  nCO + (1/2 m + n)H2 – Q

CO + H2O  CO2 + H2 + Q

For hydrocarbons with a carbon number(‘n’) higher than one, the equilibrium for the first
reaction at the outlet of the pre-reformer will almost be completely to the CO side. The CO
formed from these higher hydrocarbons will be partly converted to methane. For n=1 and
m=4; this reaction is referred to as the ‘steam methane reforming reaction’, the reverse
reaction is generally referred to as ‘methanation reaction’.

4. SHIFT CONVERSION:

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This reactor is operated at the lowest feasible temperature in order to optimize heat
recovery and the hydrogen generation from the feedstock. There are two temperature
levels at which the reactors are operated with the first one named as High Temperature
Shift Reactor operated at 350 0C and the other named as Low Temperature Shift Reactor
which is operated at 200 0C. The optimum operating temperatures increase as catalyst
ages.

The principle reaction is:

CO + H2O  CO2 + H2

5. PRESSURE SWING ADSORPTION (PSA):

PSA technology is used to remove the impurities from the reformed gas. This is achieved
by molecular sieves which adsorb the contaminants and allow the hydrogen gas to pass.
To regenerate the molecular sieves, the adsorber is depressurized. This releases the
contaminants and after pressurization the adsorber is ready for reuse. The contaminants
which are released at low pressure are collected in the purge gas drum and are used to
meet part of the heat demand of the reformer.

UNIT DESCRIPTION:

1. Reaction Section:
The feed from fractionation section is pumped by the main feed pumps to pre-heat
exchangers and then to fuel gas-fired furnace to raise the feed to reaction temperature.

There are two reactors, each containing 6 catalytic beds having hydro-cracking and
hydrogenation catalysts. The product stream coming out of the reactor system is cooled by
an air-cooler. To avoid ammonium salt deposits and corrosion, washing water is injected
upstream of the air cooler.

The cold reactor effluent is separated into three phases-

 The sour water containing ammonium salts is sent to sour water stripper.
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  The gas phase, after amine washing in the H2S stripper, is routed to a compressor
and recycled.
 The main part of liquid hydrocarbon is heated and routed to a stripper.

2. H2S Stripper:
This stripper removes H2S from the gas phase of reactor effluent. This also treats naphtha
from DHDS unit. H2S is stripped out by Medium Pressure superheated steam. The net
product from bottom of the column is pumped by stripper bottom pumps to the
fractionation section.

 The stripper overhead is condensed and corrosion inhibitor is added to protect the
condensers from corrosion. It is then separated into 3 phases in a reflux drum-
 Vapour part is fed to amine scrubber for the recovery of amine.
 Liquid hydrocarbon phase is sent to naphtha stripper for extraction of
naphtha.
 Water is separated from the liquid hydrocarbon part by virtue of density
difference and sent to sour water stripper unit.
 The stripper bottom is sent to the fractionation section.

3. Fractionation Sections:
The stripper bottom is heated in a furnace which may be gas or oil fired and then fed to
the fractionators. The feed is splitted into fractions of heavy naphtha, kerosene, gas oil
and residue.

 Overhead product- The naphtha is drawn from the overhead and is sent to the
naphtha stripper.
 Bottom product- Heat is recovered from the bottom residue and used to heat lean
amine. It also reboils the naphtha stripper. The cooled residue is finally sent to
storage.
 Gas oil- This is a side stream and heat is recovered from it and used for various
purposes like generating steam, reboiling debutaniser.
 Kerosene- Heat is recovered from this stream and used in de-ethaniser.

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The overhead vapour from the fractionator is totally condensed and slightly sub-cooled in
the fractionator overhead condenser. The hydrocarbon liquid and water phases are
separated in the fractionator reflux drum. The water phase is pumped by overhead waste
water pumps from boot and is recycled in washing water surge drum in the reaction
section. The hydrocarbon phase is pumped by fractionator reflux pumps as reflux for
fractionators overhead temperature control. Part of the hydrocarbon flows to the naphtha
stripper.

4. Naphtha Stripper:

The liquid hydrocarbon phase from H2S stripper is mixed with the heavy naphtha obtained
as the fractionator overhead.

This column removes H2S present in the feed. The naphtha stripper is reboiled by a thermo
syphon reboiler, using the gas oil coming from the fractionator.

 Overhead product stream is collected and separated into three phases-

 Vapour phase- It is mixed with the vapours from H2S stripper and fed to amine
scrubber.
 Liquid hydrocarbon phase- This is pumped by reflux pumps to run-down.
 Water- It is separated from the hydrocarbon part and sent to the sour water
stripper.
 Bottom product- It is sent to de-butaniser for exchanging its heat.

5. Amine scrubber:

The amine scrubber receives the combined sour gas from the H2S stripper reflux drum and
from the naphtha stripper reflux drum.

Lean amine from the amine regeneration unit acts as the absorbing agent of H2S. The
sweetened gases are directed to absorber de-ethaniser and the rich amine stream is
routed to the regeneration unit.

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6. Absorber de-ethanizer:

The amine scrubber sweet gas is fed to the unit. It enters a feed drum where it mixes with
the absorber bottom and de-ethanizer overhead. It is condensed and separated into three
phases-

 Liquid hydrocarbon part

 Water
 Vapour
The liquid hydrocarbon part is separated and sent to the de-ethanizer.

The purpose of the absorber is to maximize LPG recovery by separation of ethane. This is
achieved by heavy naphtha lean oil coming from the naphtha splitter bottom. The
absorber overhead vapours are sent to the LP amine absorber.

7. Low Pressure Amine Absorber:

The LP amine absorber receives the sour gas coming from the absorber.

Lean amine from the amine regeneration unit is sent to the LP amine absorber. It absorbs
any remaining H2S in the gas. The rich amine is routed to the amine re-generation unit.

8. De-butaniser:

The de-butaniser is fed by a mixture of the de-ethanizer bottom liquid and the naphtha
stripper liquid.

 Overhead product-
De-butaniser overheads are condensed and sent to reflux drum. The hydrocarbon
liquid is sent for caustic wash.

 Bottom product-
The de-butaniser bottom product is sent to the naphtha splitter.

9. Naphtha splitter:

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The naphtha splitter splits the de-butaniser bottom that is, full range naphtha (C5 -1400C)
into a light naphtha (C5 -1250C) and heavy naphtha (C5-1400C).

 Heavy naphtha is cooled by air-cooler and then chilled using propane refrigerant.
Then it is sent to storage.
 The light naphtha is cooled by using air-coolers only and sent to storage.

10. LPG Caustic Washing:

Caustic wash decreases the H2S content of the LPG according to commercial
specifications.

The LPG is contacted with a circulation of caustic soda and collected in a horizontal settler,
the caustic H2S absorber which removes the last H2S traces. The caustic soda is recovered
at the bottom of the drum. The LPG is washed with water to remove caustic traces. The
LPG is then routed to LPG water coalescer to remove any water present before sending
the LPG product to the storage.

Spent caustic is sent to spent caustic tank. Fresh caustic has to be added to the system
once 80% of the caustic is spent.

11. Lean Amine Storage:

The lean amine is received from Amine Recovery Unit. Part of the lean amine is sent to the
HP amine absorber after preheating. The other part is cooled and fed to the amine
scrubber and the LP amine absorber.

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Hydrogen Generation Unit (U-92)

The plant consists of Naptha predesulphurisation unit and a hydrogen generation unit. The
hydrogen is purified using Pressure Swing Adsorption Technology and used for
hydrogenation.

The Designed feedstock is the mixture of naphtha and FCC gasoline in a weight ratio of
80%:20%.

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 Oil Movement And Storage

OM&S

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 OIL MOVEMENT

FEED
INT. PRODUCT
CRUDE PRODUCT PRIMARY
FUEL UNITS
FINAL PRODUCTS FLO
MKTG. SLOP
OM&S
PPL
FEED
T/W
INT. PRODUCT
TTL
PRODUCT SEC.
BARGE FUEL UNITS
FLO
LPG BULK/
BOTTLING SLOP

This unit plays an important role in the storage of imported crude brought bytankers.
Refinery storage tanks are used in storage of crude oil and finishedpetroleum products.
Products from these storage tanks are dispatch for marketingby tankers, wagon, drums,
cylinders etc.The mode of dispatch depends on the distance to be traversed and on the
capacity of the pump. For the pumping of highly viscous oils, positive displacement type
pumpare used where as in the case of non-viscous oil centrifugal pump are used.

Tanks: Almost ⅓ of the refinery area is allocated for different types of tanks. They
aredesigned according to the needs of the product conservation like in the case of MS,SRN
there must be a provision to reduce the pressure produced due to thevaporization of
these products and hence these are generally stored in floating roof tanks. By design they
are four types:

1. Fixed roof tank

2. Floating roof tank

36 | P a g e
 3. Fixed cum floating roof tank

4. Doom type tank

Although several other design are also made according to the needs tanks areprovided
with
a) Manhole on the shell and roof.
b) Product inlet and outlet nozzle.
c) Drains.
d) Staircase and ladder.
e) Mechanical type level gauge.
f) Open vane with wire mesh or Breather valve or vent with flamearrestee

Depending on the service the tanks are provided with:

a) Sampling device
b) Temperature gauge
c) Jet mixing nozzle
d) Inert gas blanketing
e) Steam heating coils
Product is taken to this tank though the inlet by different pumps. There are twooutlet one
for blending and product conveying and another for drainage. Generallyproducts from
different units also contain some amount of water with them. Thisunwanted water is
drained through that outlet. Some other important operationsuch as blending is also done
by the outlets. In blending different oil are mixed up tomeet the specifications of the final
product oils such as Motor Speed Oils (MS),Diesel etc. Constant circulation of the product
of tank is done for better mixingthrough these outlets.

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 Bitumen Filling Station

BFS

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(Unit – 36)
This unit produces two types of industrial grades bitumen (85/25 and 90/15) and three
grades of straight grade bitumen (30/40, 60/70 and 80/100) from various stocks. The feed
stocks used are vacuum residue reduced crude oil, light oil, asphalt from PDA and heavy
extracts from furfural extraction unit. The bitumen’s are designated by the penetration
number. Penetration number is defined as the number of units of 1/10 mm, a standard
needle with 100gms load penetration into the asphalt mass in 5 minutes of a standard test
temperature. Thus a 80/100 bitumen means that the quantity of penetration is between 8
and 10 mm. the unit is designed for a capacity of 10000 ton/yr of industrial grade and
90000 ton/yr of straight bitumen.

The industrial grades are produced in batch process by air blowing through the feed
streams and the straight grades are produced by continuous mixing of various feed
streams. In the air blowing process, air reacts with resinous fractions, increasing its
molecular weight and converting them into Asphaltenes. The length of air blowing is to be
adjusted depending on the penetration characteristics desired.

BITUMEN:-

 INTRODUCTION:-
Bitumen is stored in tanks at a temperature around 180ºC and before filling in the
same drum it I cooled up to 100ºC. Bitumen cooling limit (BCU) consists of heat exchangers
to condensate stream, which is generated by vacuum in bitumen coolers vacuum is
maintained in the system by the steam ejects.

 OPERATING DATA:-
Inlet temperature of bitumen-180+2ºC Outlet temperature of bitumen-180+3ºC
Maximum flow rate of bitumen- 36MT/H Minimum flow rate of bitumen-16 MT/H
Bitumen inlet pressure to system -16ATA Bitumen outlet pressure to system-8ATA

 LIST OF EQUIPMENT AND THEIR FUNCTION:-

 VESSEL:- 48-B-01 Steam drum48-B-02 Seal pot
39 | P a g e
  HEAT EXCHANGERS:-48-E01A/B/C bitumen coolers48-E02A/B
vapor condensers
 EJECTOS:-48-J01A/B-Ejectors

Production of Bitumen:

The bottom product of crude i.e. RCO (Reduced Crude Oil) is taken to a vacuum distillation
unit where distillate lube is extracted. The bottom product obtain is SR (Short residue)
which is mixed with solvent propane. Then it’s taken to a de-asphalting unit where the
asphalt is taken out which is black and hard having less penetration (2-10). There is a
mixture of asphalt, SR and lube extract. There are three grades of bitumen:

1. 80/100

2. 60/70

3. 30/40

These are done based on penetration property. A needle with the help of a reference
weight is introduced inside the bitumen, and it dips the least amount for30/40 and most
for 80/100.The temperature of bitumen produced it around 140˚C. Its temperature is later
brought down in the BCU (bitumen cooing unit).

BITUMEN COOLING PROCESS:-

Bitumen is cooled in bitumen coolers by partial vaporization of DM water. Steam/DM

water is separated in stream drum. DM water is feed back into bitumen coolers and steam
is condensed in condensers .Units are located such the circulation of DM water in the
system is by gravity. Steam pressure in the stem drum is maintained 0.5642 kg/cm² (abs).

BITUMEN CIRCUIT:-

Bitumen flows through 3 vertical shells of 48E01A/B/C in series. Inlet line is 4inch and
inters connecting lines between cooler is8 inch with provision of pressure gauge and
temperature gauge. Bitumen outlet line from the system is also 8 inch and makes a goose
heek before final exit to ensure flooding of 8E01A/B/C. Bitumen bypass lines are also

40 | P a g e
provided across each bitumen cooler 2inch diameter flushing oil lines are also connected
in bitumen lines steam lose also can be connected to coolers /lines by provisions made.

DM WATER CIRCUIT:-Operating pressure of stream drum is 0.542 kg/cm² (abs) steam

drum is located above bitumen cooler to ensure high rate parallel circulation of DM water
through tube side of bitumen cooler via 3inch line. Maximum DM water level in steam
drum is controlled by funnel located 70mm above centre line of steam drum with
discharge seal pad

48B02 where water level is to maintained for maintaining vacuum steam from condensate
flow black drum via 2inch line.

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 LIQUIFIED PETROLEUM GAS

LPG

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INTRODUCTION:
LPG is a mixture of mainly propane & butane including unsaturated hydrocarbons like
propylene and butylene. As per Indian Standard specifications it is characterized as:

a) Commercial Butane.

b) Commercial Propane, and

c) Commercial Butane Propane Mixture.

LPG produced at Refinery falls in the category of Commercial butane- propane

mixture.

The areas covered are physical operations within the LPG Plant of Haldia Refinery .

I. Receipt of LPG from following Unit.

 CDU – 1

 CDU – 2

 FCCU

 OHCU

II. Storage in Bullets, Horton sphere & Mounded Bullet.

III. Dispatch by bulk Tanker.

IV. Transfer of liquid Propane to De-asphalting Unit.

43 | P a g e
Characteristics of L.P.G.

 L.P.G. produced at Haldia Refinery is a commercial mixture of propane and

butane in their saturated and unsaturated hydrocarbons with varying
compositions depending upon the nature of crude and process in use.

 The product has typical vapour pressure of 7 to 8 kg/cm2 at 380 C and

density of 0.540 to 0.552 gm/cc.

 At normal atmospheric pressure LPG exists as vapour whereas it is in the

liquid state when stored under pressure in LPG storage vessels.

 In case to leakage to atmosphere, the LPG vaporizes rapidly. This is a

potentially dangerous situation as the spilling LPG vapours can get ignited
from any source of ignition. In case liquid LPG spills out of the container it
vaporizes into very large volume, i.e. over 250 times.

 Evaporating LPG picks up heat from surroundings and cools down,

moisture present in air condenses around the area of leak.

 It is the gas heavier than the air.

 It is colourless in the liquid and in the vapour phase.

 It is practically odorless, for easy leak detection, ethyle mercaptan, an

odorant is added to LPG.

 Small quantity of its vapour in air can form an inflammable and explosive
mixture.

44 | P a g e
  CCE LICENCES:

It is obligatory to possess a valid license at all time from the Chief Controller of Explosives
(CCE), Nagpur for storage and handling of LPG.

 Receipt:

The LPG is received from following units to LPG bullets, Horton Spheres &
Mounded Bullets.

a. CDU – 1 : 9-10 m3/hr

b. CDU – 2 : 7-8 m3/hr

c. RFCC : 30-32 m3/hr

d. OHCU : 8-9 m3/hr

45 | P a g e
  LPG PUMPING FACILITIES & OPERATION:

Pump used for LPG service is basically similar to those used for other petroleum products,
taking into consideration the following specific aspects:

LPG is very penetrating and prone to leak at glands.

LPG does not possess lubricant properties.

All pumps are of cast steel construction.

Fittings of Pumps:

The fittings of LPG Pumps are described below:

Strainer:

It is essential to eliminate solid contaminants getting into system. Provided at suction line.

Vent line:

It leads from pump suction casing to flare header for removal of vapour locking as and
when required.

Pressures switch/tripping system at delivery and the pressure switch is to set to act
automatically when the pump delivery pressure comes below the set value.

Flow indicator control valve (FICV) is provided across the pump discharge and
circulation return to storage vessels. When LPG flow falls below the pre-set value, the
control valve opens and LPG gets re circulated back to storage bullets thus keeping the
capacity of the pump constant.

Pressure gauges provided at suction & discharge of pumps for the purpose of
close watch and the safe working of pump.

46 | P a g e
 Effluent Treatment Plant

ETP

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An effluent treatment plant has been installed for proper control of the
unwanted material and for the effective recovery of the oil. In ETP the TSS (
Total suspended solid), BOD (Biological oxygen demand), COD (Chemical
oxygen demand) of the water is properly regulated before water is discharged
in the surroundings.

48 | P a g e
EFFLUENT TREATMENT PRINCIPLES:

Treatment of the effluent from the various unit of the whole chemical plant is
given pridigious importance. The principle aim of ETP of Haldia Refinery is to
obtain water which is recyclable for numerous purpose in the plant and also to
make it safe for discharging in the outside environment. The effluent consisting
of effluent of oil and water is treated via a series of unit operation mainly
clarification and continuous settling. Effective chemicals and biological
treatment are also done to render flocculation, lowering BOD and COD of the
water. These treatment have been described in the upcoming section.

PROCESS DESCRIPTION:
The steps in waste water treatment are as follows:

a) Physical treatment

b) Chemical Treatment

c) Biological Treatment

PHYSICAL TREATMENT:
Waste water of refinery contains coarse suspended and floating solids, oils etc.
settle able pollutants. These need to be removed before the waste water is
subjected to chemical and biological treatment. By physical treatment the
pollutants are removed. Rakes and screens, grinder, grid chamber, grease
traps, flocculation, sedimentation, sludge pumping etc. are common physical
treatment operation in Haldia Refinery, bar screen , wire mesh, and API
separator are used for purpose for physical treatment. Effluent is first admitted
through the bar screen and wire mesh where debris, rag are removed and then
sent through grid chamber to settle out suspended solids. The purpose of these
two equipments is to protect channels. The waste water with free oil and
sludge is then routed through the API separator and then the primary
49 | P a g e
sedimentation equipment. Here the velocity of the equipment of higher
density are made to settle down and the oil of low density floats. In API around
50% to 60% of suspended solids are removed and 20% to 40% of the BOD at
20°C is achieved.

The physical separation occurs in the first 4 vessels:

1. Influent sump
Here all the effluent is brought and dumped and allowed to cool if feed is
hot.
2. Holding tank
Here sedimentation takes place,3 layers are formed.
 At the top floating oil layer is formed, which is separated.
 The second layeris of contaminated effluent.
 The bottom layer is of dust particles and sediments.
3. API/TPI
In IOCL haldia refinery two ETP plants are there:
OLD ETP and NEW ETP
In old ETP, API is used
In new ETP,TPI(Tilted Plate Incinerator) is used.
4. Equilization pond
Here the remaining separable floating layer is separated.

50 | P a g e
CHEMICAL TREATMENT:
The Chemical treatment occurs in the next two systems:

1. Flash mixture and flocculator

2. DAF system
The Chemical treatment followed by physical treatment reduces colloidal
solids, inorganic chemicals, some portion of organic chemicals and the
remaining suspending solids of the effluent.

Important unit operation and processes which are used for this purpose are:

i) Chemical coagulation, flocculation and sedimentation

ii) Filtration

iii) Ion exchange

iv) Reverse osmosis

v) Carbon adsorption

In Haldia refinery method number (I) along with oxidation of chemical both
organic and inorganic ( especially sulphide and phenolic compound) by chlorine
is followed. Coagulation is the process in which chemicals which is termed as
coagulants are added to an aqueous system to create rapidly settling aggregate
out of present. Flocculation is the second stage in the formation of this
aggregate which is achieved by gentle and prolonged mixing. Over here
coagulation occurs in pre aeration chamber. FeSO4 solution and lime solution
are added in pre aeration chamber. Positively charged iron ions neutralize the
negative ion of emulsified oil and hence releases the oil from water. These iron
ions are hydrolyzed by hydroxides to form Fe (OH)2 FLOC's.

Dissolved O2 in the effluent oxidizes Fe(OH)2 to Fe(OH)3 floc which settles at

faster rate than Few(OH)2. For highest efficiency a rapid and intimate mixing of
Fe(OH)3 / Fe(OH)2 flocs with effluent is necessary before flocculation process
51 | P a g e
begins, which is done in flash mixer where a motor driven stirrer is rotating
continuously.

Flocs so formed are too light to settle under gravity, thus from the flash mixer
chamber the effluent goes to clariflocculator where slow stirring is done by two
continuously rotating motor driven stirrer thus enabling flocculation i.e.
agglomeration of small flocs.

BIOLOGICAL TREATMENT:
The biological treatment occurs in the bio towers.

After physical and chemical treatment waste water is to biological treatment

under aerobic condition for further reduction of organic polltant. The principles
involved are to utilize naturally occurring bacteria to eat away or oxidize
organic impurities thereby refucing the concentration of pollutants. These
bacteria simultaneously get bioderaded. The excess of bacteria is removed
from tje system periodically. The basic biochemical reaction for the
stabilisation of organic impurities under aerobic composition by micro
organism in waste water

Organic impurities + microbes + O2 = A more microbe + CO2+H2O + waste

energy

The common system for biological treatment are Trickling filter and Activated
sludge tank also called as aeration tank or bio-reactor. Both are used in Haldia
refinery.

In case of Trickling filter (bio filter) system, waste water is sprayed on the bed
of stones. The aeration is form on the bottom of the stones upwards, due to
temperature difference of water and the ambient air, bacteria grows on the
stone surface as a film which eats away organic impurities. These bacteria
decay and wash out periodically. Fresh bacteria grow again on the stones.

52 | P a g e
In case of activated sludge tank, the bacteria is continuously fixed with waste
water and aerated by motor operated aerators. Here also bacteria eat away
impurities. The bacteria water is then sent to clarifier from aeration tank where
bacteria mass separated from water. The bacteria mass is recycled back to
aeration tank to maintain required level of bacteria in aeration tank.

53 | P a g e
 CONCLUSION

Industrial training is very much important from chemical engineering point of view. Here
all units are very much important and every unit has an important objective.

From CDU, we are know about physical separation of various products and various process
equipment and unit operation.

From VDU, we know about physical separation of various products and various process
equipment and unit operation. Here we are seeing how to use vacuum.

From DHDS, KHDS & SRU, we get wide knowledge of sulfur recovery which is much
important for environmental aspect and we know how to remove sulfur and various
process equipment and unit operation.

Today LPG and Gasoline are more important for automobile and domestic purpose, but
from CDU, we get less amount of LPG and Gasoline than our requirement. So, FCCU gives
LPG and Gasoline which is more important than our requirement. To increase octane
number CRU plays a vital role.

Haldia Refinery takes an important role for Lube oil production and separation of
aromatics wax and asphalt from lube oil which is much needed. Hence it is also known as
Lube Oil Refinery.

This plant is the application of mass transfer, heat transfer, fluid mechanics and
thermodynamics which is the heart of chemical engineering.

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