INDIAN OIL CORPORATION LIMITED

HALDIA REFINERY
SUMMER TRAINING PRESENTATION

SUBMITTED BY: RAVI KUMAR FULWA

BRANCH : CHEMICAL ENGINEERING
FROM : MNIT JAIPUR
 List OF REFINERIES OF IOCL
• Guwahati (Assam)
• Barauni (Bihar)
• Koyali,Baroda (Gujarat)
• Haldia (W.B.)
• Mathura (U.P.)
• Panipat (Hr.)
• Paradeep (Orissa)
• Bongaigaon (Assam)
• Digboi (Assam)
 Haldia refinery
Haldia Refinery, one of the eight operating refineries of Indian Oil, was commissioned in
January 1975. It is situated 136 km downstream of Kolkata near the confluence of river
Hoogly and Haldi. From an original crude oil processing capacity of 2.5 MMTPA. Capacity
of the refinery was increased to 2.75 MMTPA in 1989-90, and to 3.75 MMTPA in 1997
with the installation/commissioning of the second Crude The present refining capacity is 7.5
MMTPA (Mega Metric Tonnes per Annum) which is producing BS IV standard products. It is
tipped to increase its capacity to 7.9 MMTPA with a modification to BS VI standard
products.
HALDIA REFINERY UNITS

 Once Through Hydrocracking Unit (OHCU)

 Fuel Oil Block (FOB)
 Lube Oil Block (LOB)
 Diesel Hydro-Desulphurisation Unit (DHDS)
 Bitumen Filling Station
 Effluent Treatment Plant (ETP)
 Oil Movement And Storage (OMS)
Once through hydrocracking unit

This block includes following four units:

1.Once through hydrocracking unit
2.Feed preparation unit
3.Hydrogen generation unit
4.Nitrogen generation unit
Once through hydrocracking unit

• Feed : VGO (spindle oil ,intermediate oil ,light oil )

• Catalyst used : CO-MO
• Products : cuts like kerosene ,diesel and in small fraction lighter
cuts also.
• Steps:
1. Hydrotreating
2. Hydrocracking
The heavier feedstocks are cracked in the presence of hydrogen to produce more
desirable products . the process employs high pressure , high temperature ,
catalyst and hydrogen .the products from this unit is directly sellable because S ,N
contents are removed during hydro-treating.
Feed preparation unit

• This is the feed preparation unit. The UCO (unconverted oil) from fractionator
in OHCU is the feed to this unit
• The products are 50 N,150 N,500 N,750 N lube which are sent to LOB (lube
oil block).
Hydrogen generation unit

• The following processes occur in this unit:

• 1. Feed pre-desulphurisation
• 2. Feed desulphurisation
• 3. Preforming and reforming
• 4. Shift conversion
Nitrogen generation unit
 Fuel oil block
This block includes following units:-
1. Desalter
2. Pre fractionator
3. Main fractionator
4. Stripper
5. Stabilizer column
6. Lpg caustic wash and merox reactor
7. De-ethaniser
8. Naptha splitter
9. Naptha hydrotreating unit
10. Catalytic reforming unit
Crude Distillation Unit (I and II)
• Feed: Crude oil
• Purpose: Separation of crude into different cuts by atmospheric distillation.
• Products: Liquid Petroleum Gas (LPG), Fuel gas (C1-C2), Naphtha,
Kerosene/ATF, Diesel, Jute batch oil, Reduced crude oil.
Before distillation is done, crude is heated to 120 0C in a set of pre-heat
exchangers and fed to desalter and this desalted crude is heated up to
2000C pretreated in a prefractionation column. Crude further heated to
260 0C in heat exchanger and then to 350 0C in a furnace.
Naphtha Hydro-treating Unit (NHDT)

• Feed: Naphtha
• Purpose: Removal of sulfur in order to prevent the poising ,corrosion, deactivation of catalyst
• Catalyst : Ni-Mo catalyst on Alumina
• Products: Straight run naphtha for CRU.
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 desulphurisation reactor where
Ni-Mo oxides on alumina are used as catalyst. Hydrogenation occurs leading to formation of
H2S which is stripped out. Hydro treated naphtha is sent to catalytic reforming unit.
 Catalytic Reforming Unit (CRU)
• Feed: Straight Run naphtha from NHDT
• Purpose: To increase the octane number which improves the anti-knocking property of the fuel.
• Catalyst : platinum
• Product: Reformed Naphtha
The hydro-treated naphtha is heated and completely vaporized in a furnace. It enters reactor filled with
platinum catalyst where catalytic reforming reactions like dehydrogenation, isomerization and cracking take
place. There are three Reactors and furnace for the same purpose as the reaction is endothermic in nature.
Feed has to be re-heated before being passed to 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-Desulphurisation Unit (KHDS)

• Feed: Kerosene distillate cut produced from ATU.

• Purpose: To remove Sulphur from kerosene distillate cut produced from ATU
• Catalyst: Co-Mo
• Product: Treated kerosene/ATF
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
 LUBE OIL BLOCK
This block includes following units:
1. Vacuum distillation unit (VDU1)
2. Propane de-ashphalting unit
3. Vis-breaking unit
4. Residual super critical extraction unit
5. Furfural extraction unit
6. Catalytic isomerization unit
7. Hydrotreating unit
Vacuum Distillation Unit (VDU-I)

Feed : Reduced Crude Oil (RCO)

Products : Gas oil/Diesel

Spindle Oil
Light Oil
Inter Oil
Heavy Oil
Vacuum Residue or Short Residue
It’s main purpose is to distil the Reduced Crude Oil obtained from Atmospheric Distillation
Column, under vacuum for preparing feed of Lube Oil.
Propane De-asphalting Unit (PDA)
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
Purpose : to remove lighter cuts
presents in VR

product:
Extract phase: DAO
Raffinate: ashphalt
Vis-breaking Unit (VBU)

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
Products : fuel gas
gas oil
naptha
Furfural Extraction Unit (FEU)

Feed : Vacuum distillates

Purpose :to increase viscosity index
Products :
BN-Raffinate phase
Extract phase (rich in long chain aromatics)
 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
isomerization of n-paraffins to iso-paraffins.
Feed : BN Raffinates
Product: iso-paraffins
Hydro-finishing unit

Feed : iso-paraffins
purpose : to remove the S ,N present in feed and
further iso-merization
To saturate the unsaturates and formed stable product
to remove lighter products formed during reactor 1

Product: lube oil basestock

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 Oil movement and storage
This unit plays an important role in the storage of imported crude
brought by tankers. Refinery storage tanks are used in storage of
crude oil and finished petroleum products.
Products from these storage tanks are dispatch for marketing by
tankers, wagon, drums, cylinders etc. The mode of dispatch depends
on the distance to be traversed.
 The main functions of OMS Unit are as follows
• Receipt and storage

Crude oil from tankers

Intermediate and finished products from process units.

• Preparation and supply of feed to various units

• Blending of products

• Dispatch of products

• Supply of fuel oil to furnaces

• Unloading, storing, supplying

various solvents and chemicals to units

• Recovery of steam condensate

• Accounting of petroleum products .

Storage tanks

There must be a provision to reduce the pressure produced due to the

vaporization of these products while storing . According to lighter to heavier
tanks are classified as follows:
1. Fixed roof tank
2. Floating roof tank
3. Fixed cum floating roof tank
4. Dome shaped tank
Product is taken to this tank though the inlet by different pumps. There
are two outlet one for blending and product conveying and another for
drainage. Generally products from different units also contain some
amount of water with them. This unwanted water is drained through
that outlet. Some other important operation such as blending is also
done by the outlets. In blending different oil are mixed up to meet the
specifications of the final product oils such as Motor Speed Oils (MS),
Diesel etc.
 Ways of Transportation
• Pipeline: The most commonly used form of transportation is through pipelines. They are
typically used to move crude oil from the wellhead to gathering and processing
facilities and from there to refineries and tanker loading facilities. Pipelines require
significantly less energy to operate than trucks or rail and have lower carbon footprint
• Rail/ Wagon: The relatively small capital costs and construction period make rail
transport an ideal alternative to pipelines for long distance shipping. However, speed,
carbon emission and accidents are some significant drawbacks to rail transport.
• Truck: While the most limited oil transportation method in terms of storage capacity,
trucks have the greatest flexibility in potential destination. Trucks are often the last step
in the transport process, delivering oil and refined petroleum products to their intended
storage destinations.
• Ship: Where transport over land is not suitable, oil can be transported by ship. The
drawbacks are typically speed and environmental concerns.
 Bitumen filling station
Different grades of bitumen are classified on basis of kinematics viscosity , penetration index
absolute viscosity ,softening point ,flash and fire point test etc that are as follows:
1. VG -10
2. VG-30
3. VG-40
Ashphalt have very low penetration index so blending & cutterstocks are used where no chemical reaction take
place only physical dilution will be occurred.
Cutterstock : extract phase product of furfural extraction unit (long chain aromatics)
To make the bitumen more stable and adhesive , emulsion is made by adding the chemicals , emulsifier , solvent like
kerosene ,water
 EFFLUENT TREATMENT PLANT (ETP)

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.
Treatment of the effluent from the various unit of the whole chemical plant is given
prodigious 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.
 Major Operations in Effluent Treatment Plant

• Physical treatment : Dilution, Sedimentation, Filtration, Aeration

• Chemical treatment: Sulphide/ Spent Caustic Treatment: H2O2 Addition,
Coagulation using Poly-Aluminium Chloride(PAC)
• Biological treatment: Bio Tower & Aeration Tank
• Tertiary treatment: Chlorination an Filtration
• RO Operation: For boiler feedwater supply
• Sludge thickening: Centrifuge operation
The steps in waste water treatment are as follows:
1.Physical treatment
2.Chemical treatment
3.Biological treatment
Chemical added during the treatment of waste water are as follows:
H2SO4 +NAOH+NUTRIENTS add in ph adjustment tank
POLY ALUMINIUM CLORIDE +H202+ DE OILY POLY ELECTROLITE add in flocculator
UREA add in aeration tank

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Diesel hydro desulphurization
This block includes following units:
1. Motor Sprit Quality Upgradation Unit
2. Residue Fluidized Catalytic Cracking Unit
3. Vacuum Distillation Column
4. Diesel Hydro De-sulphurisation Unit
5. Nitrogen plant air plant
6. Amine regeneration unit
7. Sour water stripper
8. Sulphur recovery unit
7/11/19
 Diesel Hydro-Desulphurization Unit (DHDS)
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.
Vacuum Distillation Unit (VDU II)

• It is used for processing of High-Sulphur Crude. Reduced crude received from

the atmospheric unit is the feed stock of VDU. Basically, reduced crude oil
(RCO) cannot be distilled at the CDU operating conditions as they are very
heavy. And if temperature is increased, then excessive coke formation occurs.
So it is distilled under vacuum (70 – 80 mmHg) which will decrease the boiling
points of the heavy hydrocarbons and can be separated into GO, SO, LO, IO,
HO, Vac slop, VR.
Residue Fluidized Catalytic Cracking Unit (RFCCU)
The feedstock to RFCCU is usually that portion of the crude oil that has an initial boiling point of 340°C or
higher at atmospheric pressure and an average molecular weight ranging from about 200 to 600 or
higher. This portion of crude oil is often referred to as heavy gas oil or vacuum gas oil (HVGO). The RFCCU
process vaporizes and breaks the long-chain molecules of the high-boiling hydrocarbon liquids into much
shorter molecules by contacting the feedstock, at high temperature and moderate pressure, with a fluidized
powdered catalyst. Products obtained are more valuable Gasoline, Olefinic gases and other products
 Motor Sprit Quality Upgradation Unit (MSQU)

• The unit is commissioned with the aim to produce superior quality gasoline. The main
objective of the unit is to convert the straight chain hydrocarbons, C5 - C6 paraffin
to branch chain, or olefins to improve the octane number. As benzene is carcinogenic
so benzene saturation is an important factor in this unit. Reactions of type
desulfurization, isomerisation, and benzene saturation olefin saturations are done in
these units. The light FCC gasoline obtained after gasoline splitting in unit 87 is
blended with heavy reformate from unit 85, isomerate from unit 86, heart cut FCC
gasoline from unit 87, and heavy gasoline after hydrodesulphurization in unit 87
are blended proportionately for octane improvement and desulfurization in the
blending header to get MS of desired octane number.
 Sulphur Recovery Unit (SRU)
The main reaction occurring in the burner is
H S + 1.5 O  SO + H O + heat
2 2 2 2

A major part of the residual H S combines with SO to form sulphur according to

2 2

the reaction

H S + SO  1.5 S + 2H 0 – heat
2 2 2

This is called Claus reaction.

Hydrogen Generation Unit (HGU)

• Used for generation of Hydrogen for quenching and de-sulfurization.

HGU can be divided into:

• Pre-desulphurization
• Desulphurization
• Reforming
• CO - conversion
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 amine absorbers. Absorbent used is
diethanol amine.
THANK YOU