VOCATIONAL TRAINING REPORT

(MAY-JUNE 2014)
AT

INDIAN OIL CORPORATION LIMITED

GUJARAT REFINERY

SUBMITTED BY:SAGAR CHAWLA

CHEMICAL ENGINEERING (B.TECH 2nd year)
IIT GANDHINAGAR

ACKNOWLEDGMENT
The vocational training at IOCL world class refinery helped us to get as insight and
practical knowledge of refinery process. After going through this training our
practical knowledge increased and we are more acquainted with industrial
environment due to exposure given here.
I am thankful to everyone helped during our training period. First of all we are
thankful to Mr. AC Shekhar for giving us the opportunity to be a part of the IOCL
industry. I am thankful to Mr. MM Parmar for helping and teaching us. I am very
thankful to all the employees who gave us training and valuable knowledge on
control panel and in Plants.
Also sincere thanks to transport staff that helped us a lot during our training
period.
Yours Sincerely
Sagar Chawla

Contents
a) Introduction of Gujarat Refinery . . . . . . . . . . . . . . . .

b) Major Units of Gujarat Refinery

. . . . . . . . . . . . . . . .

c) Atmospheric Distillation Unit 1(AU 1)

. . . . . . . . . . . .

d) Catalytic Reforming Unit (CRU) . . . . . . . . . . . . . . . . .

e) Fluidized Catalytic Cracking Unit(FCC)
f) Oil Movement & Storage (OMS)

5
17

. . . . . . . . . . . . 24

. . . . . . . . . . . . . . . . . 35

INTRODUCTION OF GUJARAT REFINERY

Initially the refinery was setup with a capacity of 2 million metric ton per
annum for annum of processing of ankleshwar crude.
The 1st oil AU-1 of MMTPA capacity was commissioned in October 1965.
The 2nd crude distillation unit AU-2 of MMTPA capacity was commissioned
in September 1966.
Subsequently with avaiblity of crude oil from north Gujarat field, the 3rd
crude oil distillation unit AU-3 was commissioned in September 1967 to
process 1 MMTPA of 50:50 mixture of ankleshwar and north Gujarat crude.
Thus the refining capacity became 3 MMTPA at the time with the house
modification the capacity of the refinery was further increased by 40 % to a
level of 4.3 MMTPA by 1974-75, which enabled processing of increased
availability of Gujarat crude
In 1966, catalytic reforming unit was installed for production of high octane
motor spirit as well as production of aromatic ( benzene and toluene) feed
stock. Subsequently, the xylene reformate for production xylene at IPCL.
In December 1968, udex Plant was commissioned for the production of
benzene and toluene based on aromatic feed stock available from CRU.
In view of the demand of the petroleum product in the country as well as
the supply pattern if this area the refinery was expanded adding another 3
million ton crude distillation unit AU-4 which is extended to 5 MMTPA.
Along the downstream processing units kije vacuum distillation visbreaker
and bitumen blowing unit during the year 1978-79 to process imported
crude.
After stabilization of crude oil production from Bombay high fields and with
the view to absorb the same, this unit started processing Bombay high
crude in addition to imported crude with effect from 1979-80.
To recover high value product from the residue, the secondary processing
facilities consisting if fluidized catalytic cracking GCC of 1 MMTPA capacity
along with feed preparation unit FPU-1 of MMTPA capacities were
1

commission in December 1982, refinery also set up pilot distillation

facilities for the production of n-heptanes and aluminum oil.
For the conservation of heavier ends of crude oil high value superior
products, a state of the hydrocracker unit, nitrogen unit, sour water
stripper and sulphur recovery unit also with a separator power generation
with the gas turbines.
In hydrocracker unit the feed (VGO) is converted fully into quality product
of which middle distillate (ATF, diesel) yield about is above 80 %.
Along hydrocracker project, visbreaker unit the capacity was increased
from 1.6 MMTPA with the absorption of soaker technology in order to
liquidate high quantity of vacuum residue, so as to produce finished
product LSHS.
In the year 1965, food grade hexane plant was commissioned for the
production of 28000 TPA food grade hexane.
Diesel hydro-de-sulfurization(DHDAS) along with the hydro generation unit
and sulphur recovery unit was enabled refinery to produce low sulphur
diesel. The sulphur content in diesel was brought down from 1 % to 0.25 %
level.
Subsequent second reactor in DHDS unit was commissioned in November
2000 to enhance ultralow S HSD production with a S content of 0.05 %.
A common central effluent treatment plant was commissioned with a
capacity of 1500 m3/hr, in June 1999. To meet the stipulated discharge.

Major units of Gujarat Refinery

Atmospheric distillation unit(Crude distillation unit)
o Gujarat refinery has five primary distillation unitsAU1, AU2, AU3, AU4 &AU5 with combined crude processing of 13.7
MMPTA and flexibility of processing indigenous of imported crude.
o The various products obtained from crude distillation are:1). Methane, ethane and propane mixture as refinery fuel gas.
2). Liquefied Petroleum Gas (LPG)
3).Aviation turbine fuel (ATF)
4). Super kerosene (SK)
5). High speed diesel (HSD)
6). Residue crude oil (RCO)
Catalytic Reforming Unit
o Gasoline fraction product from distillation units containing
naphthalene and paraffin type of hydrocarbons are chemically
transformed into aromatic type of hydrocarbons having higher
octane number.
Diesel hydro de-sulfurization unit(DHDS)
o The DHDS process is an environment friendly technology.
o Gujarat refinery commissioned DHDS unit in june 1999.This unit
reduces sulphur content in HSD to the level of 0.05 %.
Fluidized Catalytic Cracking Unit
o Unit was commissioned with a capacity of 1 MMTPA in 1982 Gujarat
refinery.
o Catalytic cracking is the most important process for converting low
value, bottom of the barrel, heavy oils into high value lighter
products, in particular gasoline.
3

 Hydro Cracker Unit

o To upgrade the heavy residue to valuable middle distillate Gujarat
refinery has setup a hydro cracker plant with all associated units like
feed preparation unit, hydro cracker unit, nitrogen plant, power
plant, sulphur recovery unit and waste water treatment plant.
o The hydro cracker unit is designed to process 1.2 MMT of vacuum gas
oil per annum produced from feed preparation unit. The unit
converts the vacuum gas oil into products like diesel, kerosene and
naphtha, LPG etc. By cracking process in presence of hydrogen. The
products generated are of superior quality.
o The unique feature of the hydrocracker unit is its capability to totally
convert the feed into diesel and lighter products i.e. no residue cones
out of the unit.
Linear Alkyl Benzene (LAB)
o LAB is an important and vital raw material, which is solely
determines the cleaning action of detergent
o The quality LAB produced is the best in our country on various
parameters, making it a preferred grade among the customers.
o Lab has also been exported to various countries and has evoked
excellent response from overseas buyers.
Motor Spirit Quality Unit(MSQU)
o Auto fuel policy guidelines stated to supply BS 2nd and EURO 3rd
great fuel in ahemdabad and surat cities by 1st April 2005 and EURO
4th great fuel by 1st april 2010.
o In this unit for the 1st time Gujarat refinery adopted continuous
catalytic reforming unit regeneration technology (CCR) technology.
Different products of Gujarat refinery
o LPG
o BENZENE
o TOLUENE
o NAPHHTA
o MOTOR SPIRIT
4

o
o
o
o
o
o
o
o
o

AVIATION TURBINE FUEL

SUPERIOR KEROSENE
HIGH SPEED DIESEL
LIGHT SPEED DIESEL
LOW SULPHUR HEAVY STOCK
FUEL OIL
BITUMENT
N-HEPTENE
ALUMININIUM ROLLING

GUJARAT REFINERY-GR 1
This unit has 3 sub units under it namely:1). Atmospheric Distillation unit (AU1&AU2)
2). Catalytic Reforming Unit (CRU)
3).Atmospheric Distillation unit (AU 5)

ATMOSPHERIC UNIT 1 (AU 1)

Introduction of the Atmospheric Distillation Process
Distillation: Separation by distillation implies a difference in boiling points of two or
more materials.
Materials separate by detecting a difference in physical properties like
color, size, weight and shape.
It is difficult to separate some pure compounds from the complex mixture
of components in crude oil by distillation alone. There are other methods of
separation used in a refinery for example, extraction with a solvent,
crystallization and absorption.
Principles of Distillation
When a solution of two or more components is boiled the lighter component (the
one most volatile or the one with the greatest tendency to vaporize) vaporizes
preferentially.
Two component mixture is contained in a vessel When heat is add until the more
volatile material ( red dotes ) start to vaporize. Now the vapor contains a higher
proportion of red dots than dose the original liquid.

Equilibrium in composition will be established at a given temperature and

pressure. By equilibrium we mean there is a given concentration as red dots" in
the vapor and in the liquid depending upon the original concentration of each
component in the liquid and their respective properties in relation to each other.
This results in the vapor above the liquid being relatively rich in the lighter (more
volatile material) and the liquid is left with proportionately more of the less
volatile ( heavier liquid ).
Basic distillation concept of refinery process:By cooling the over head vapor, we condense and remove it from the original
mixture thus to have made a partial separation, partial because you will note that
there are a few plus dotes" in the distillate product.

This has occurred because at the temperature and pressure we are conducting
the distillation; the
heavier component still vaporizes to some extent this is
because the components of interest in a given distillation usually have fairly close
boiling points. Therefore, to purify the distillate product, we may have to conduct
a second distillation unit, we can continue to cascade these simple distillations
until we achieve the desired purity of product.
Tower Sections:The upper two stages are called rectifying stages. These below the feed are called
stripping stages.

The upper rectifying section increases the purity of the overhead product while
the stripping section increases recovery of the overhead product. In many cases,
the bottom product is the one of primary interest. For the bottom, or heavy,
product the rectifying section improves purity.

Equilibrium Stage:
A stage should be designed in such a way as to provide intimate contact, or
mixing, of the rising vapor and the descending liquid. The concept of an
equilibrium stage is converted to an actual mechanical separation tray by using an
efficiency factor which is less than one and depends on the tray design.
The design of trays has taken many forms
Some common ones are:

Valve trays,

bubble cap trays

sieve trays

Alternate designs include packing instead of trays

Various kinds of packing have used, some of which are :

pall rings,

saddles and

mesh

RefluxReflux is the liquid flowing back down the tower from each successive stage.
Types of Reflux
Cold Reflux:Cold reflux is defined as liquid that is supplied at temperature a little below that
at the top of the tower Each pound of this reflux removes a quantity of heat equal
to the sum of its latent and sensible heat required to raise its temperature from
reflux drum temperature to the temperature at the top of the tower A constant

quantity of reflux is recirculated from the reflux drum into the top of the tower It
is vaporized and condensed and then returns in like quantity to the reflux.

Hot Reflux:It is the reflux that is admitted to the tower at the same temperature as that
maintained at the top of the tower. It is capable of removing the latent heat
because no difference in temperature is involved.
Internal Reflux:It is the reflux or the overflow from one plate to another in the tower, and may be
called hot reflux because it is always substantially at its boiling point. It is also
capable of removing the latent heat only because no difference in temperature is
involved.
Circulating Reflux:It is also able to remove only the sensible heat which is represented by its change
in temperature as it circulates. The reflux is withdrawn and is returned to the
tower after having been cooled.
Side Reflux:This type of reflux (circulating reflux) may conveniently be used to remove heat at
points below the top of the tower. If used in this manner, it tends to decrease the
volume of vapor the tower handles.

10

CRUDE DISTILLATION:The purpose of crude oil distillation is primarily to split the crude into several
distillate fractions of a certain boiling range. Sharpness of fractionation is of
secondary importance. The number of trays used for crude distillation is very
small compared to most other distillations. A crude distillation tower, producing
6 fractions has only 40 to 50 trays. Crude can be separated into gasoline, naphtha,
kerosene, diesel oil, gas oil, and other products, by distillation at atmospheric
pressure. Distillation is an operation in which vapors rising through fractionating
decks in a tower are intimately contacted with liquid descending across the decks
so that higher boiling components are condensed, and concentrate at the bottom
of the tower while the lighter ones are concentrated at the top or pass overhead.
Crude is generally pumped to the unit directly from a storage tank, and it is
important that charge tanks be drained completely free from water before
charging to the unit. If water is entrained in the charge, it will vaporize in the
exchangers and in the heater, and cause a high pressure drop through that
equipment. If a slug of water should be charged to the unit, the quantity of steam
generated by its vaporization is so much greater than the quantity of vapor
obtained from the same volume of oil, that the decks in the fractionating column
11

could be damaged. Water expands in volume 1600 times upon vaporization at

100C at atmospheric pressure.
Process Description
A. Heat Exchange
In order to reduce the cost of operating a crude unit as much heat as possible is
recovered from the hot streams by heat exchanging them with the cold crude
charge. The number of heat exchangers within the crude unit and cross heat
exchange with other units will vary with unit design. A record should be kept of
heat exchanger outlet temperatures so that fouling can be detected and possibly
corrected before the capacity of the unit is affected.
B. Crude Flashing
Desalted crude is heat exchanged against whatever other heat sources are
available to recover maximum heat before crude is charged to the heater, which
ultimately supplies all the heat required for operation of the crude unit. The heat
input is controlled by having the heater transfer temperature reset flow of fuel to
the burners. The heater transfer temperature is merely a convenient control, and
the actual temperature, which has no great significance, will vary from 325C to
as high as 430C, depending on the type of crude and the pressure at the bottom
of the fractionating tower. It is noteworthy that if the quantity of gasoline and
kerosene in crude is reduced, the transfer temperature required for the same
operation will be increased, even through the lift is less.
C. Fractionation
Flashed vapors rise up the fractionating column counter current to the internal
reflux flowing down the column. The lightest product, which is generally gasoline
passes overhead and is condensed in the overhead receiver. (Should the crude
contain any non-condensable gas, it will leave the receiver as a gas, and can be
recovered by other equipment, which should be operated to obtain the minimum
flash zone pressure.) The temperature at the top of the fractionators is a good
measure of the endpoint of the gasoline and this temperature is controlled by
12

returning some of the condensed gasoline as reflux to the top of the column.
Increasing the reflux rate lowers the top temperature and results in the net
overhead product having a lower endpoint. The loss in net overhead product
must be removed on the next lower draw try. This will decrease the initial boiling
point of material from this tray. Increasing the heater transfer temperature
increases the heat input and demands more reflux to maintain the same top
temperature.
D. Product Stripping
The flashed residue in the bottom of the fractionators and the side cut products
have been in contact with lighter boiling vapors. These vapors must be removed
to meet flash point specifications and to drive the light ends into lighter and more
valuable products. Steam, usually superheated steam, is used to strip these light
ends. Generally only enough steam is used to meet a flash point specification.
While further increases in the quantity of steam may raise the IBP of the product
slightly, the only way to substantially increase the IBP of one product is to
increases the yield of the next light product. (Provided, of course, the
fractionators has enough internal reflux to make a good separation).

Description of the process of AU-1 of Gujarat refinery:Crude is preheated upto 130 to 140 Deg.C(desalting temperature) with
ATF,HSD(PRODUCT+CR), Kerosene and RCO. Desalting water, preheated by heat
exchange with desalter effluent is injected into the crude at desalter inlet or
alternatively at T1 respectively. The desalted crude picks up additional heat by
further heat change with diesel CR and RCO, before it enters the preflash column
K1.
The preflash column has 9 trays below and 19 trays above the flash zone. Reboil
heat is supplied to column K1 by one cell of the twin cell heater F1. The overhead
vapours are condensed in condenser T11 and collected in E1. A part of the E1
13

gasoline is sent to the stabilizer K5 while the rest is returned to column K2 as

reflux. The bottom product from K1 is further heated and vaporized in furnace F1
and is introduced into flash zone of main fractionators K2.
Six stripping trays are provided below the flash zone where the reduced crude is
stripped with steam to remove the lighter constituents. The stripping section
vapours together with the vaporized portion of the feed are fractionated on the
trays above zone to yield liquid side products and vapour over head stream.
HSD is withdrawn as the first side stream from 14th tray along with HSD CR. The
product stream enters the stripper K3. The HSD and HSD CR are cooled by heat
exchanger with crude before it is routed to storage/returned to main
fractionators respectively.
Kerosene and Kero CR are withdrawn from 26th tray. They are cooled by heat
exchanger with crude after which the circulating reflux is returned to K2 and the
product is cooled and sent to storage.
ATF is withdrawn from 34th tray and after exchanging heat with crude is further
cooled and sent to storage. The overhead naphtha vapors are condensed in the
condenser T12. E2 gasoline partly along with E2 gasoline(AU 2) is sent to V1 or to
CRU tank and the balance is returned to K2 as reflux.
The stripped RCO from K2 bottom exchangers heat with crude and are then
cooled in coolers before sending to storage.
Unstablized gasoline(E1 gasoline) is sent to stabilizer K5 along with CRU drag
stream. It is preheated by successive heat exchanger with RCO and K5 bottom.
The overhead from K5 is condensed and a part is withdrawn as LPG and rest is
sent to column as reflux. The reboil heat to K5 is supplied from K5 i.e. K5 bottom,
along with K5 bottom from AU2 after preheating feed is routed to K8.
Naphtha rerun section
This feed to K8 consists of the following streams:
o E2 gasoline from column K2(AU1)
14

o
o
o
o
o
o

K4 bottom naphtha & E2 gasoline

Bombay high naphtha from OM&S
E2 gasoline from column K2(AU2)
Light naphtha from AU5 stabilizer bottom
Light naohtha from AU4 stabilizer bottom
K5 bottom after feed preheating K5 feed

The quantity of BH naphtha is varied so as to maintain V1 level. THE first six

streams are combined in MMTPA1 and preheated on E210 A/B & T2 (bottom) by
heat exchanger with K9 bottoms. Provision has been given to take E2 directly as
K8/K9 feed. The preheated naphtha is heated in T2E with IPCL naphtha from K10,
and along with K5 bottom. It is further heated up in E202 A/B by Mp steam before
entering in K8. Furnace F4 and E303 provided necessary reboil heat duty for
column K8.
The IBP-70 Deg.C cut naphtha is recovered as overhead vapours and condensed in
T15 A/B and T16 A/B and are collected in E7 and E8. A part of liquid from E7 and
E8 is sent as run down to GHP/MS/GN/GOP while the rest is sent to K8 as reflux.
In addition to this a new provision was made to dispatch naphtha to panipat
refinery ex caustic wash. K8 top can also be sent to isomerization init before
caustic wash.
The bottom product from K8 is directly sent to column k9 that is reboiled by
furnace F3, F5 and E303. The 70-90 Deg. C cut naphtha is recovered as overhead
vapours and condensed in the condensers T17 A/B/C and is collected in E9. A part
from E9 is sent to column as reflux and rest is sent to rundown to light charge
stock/GN/MS.

15

Figure: Process Flow Diagram of Atmospheric Distillation

16

CATALYTIC REFORMING UNIT (CRU)

Introduction of Catalytic Reforming Process: The aim of this process is to improve the octane number of a naphtha
feedstock by changing its chemical composition.
Catalytic reforming is considered the key process for obtaining benzene,
toluene, and xylenes (BTX). These aromatics are important intermediates
for the production of many chemicals.
Hydrocarbon compounds differ greatly in their octane ratings due to
differences in structure.
In general, aromatics have higher octane ratings than paraffins and
cycloparaffins.
Increasing the octane number of a low-octane naphtha fraction is achieved
by changing the molecular structure of the low octane number
components.
The feed to a catalytic reformer is normally a heavy naphtha fraction
produced from atmospheric distillation units.
The naphtha must be hydro treated to saturate the olefins and to
hydrodesulfurize and hydrodenitrogenate sulfur and nitrogen compounds.
Olefinic compounds are undesirable because they are precursors for coke,
which deactivates the catalyst. Sulfur and nitrogen compounds poison the
reforming catalyst.
Feeds with a high naphthene content are easier to aromatize than feeds
with a high ratio of paraffins.
Feeds with higher end points (200C) are favorable because some of the
long-chain molecules are hydrocracked to molecules in the gasoline range.
The catalysts generally used in catalytic reforming are dual functional to
provide two types of catalytic sites, hydrogenation-dehydrogenation sites
and acid sites.
The former sites are provided by platinum and the latter is provided by an
alumina carrier.

17

 The two types of sites are necessary for aromatization and isomerization
reactions.
Bimetallic catalysts such as Pt/Re have better stability, increased catalyst
activity, and selectivity.
Trimetallic catalysts of noble metal alloys are also used.
These catalysts can tolerate higher sulfer naphtha feeds (>1 ppm)
Many reactions occurs in the reactors.
aromatization reactions, which produce aromatics.
Isomerization reactions, which produce branched paraffins.
Hydrocracking, these is not directly involved in aromatics formation.

Reactions of Catalytic Reforming Unit:1.) Aromatization

The two reactions directly responsible for enriching naphtha with
aromatics are:a) Dehydrogenation of naphthenes

b) Dehydrocyclization of paraffins to aromatics

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2.) Isomerization
Isomerization reactions may occur on the platinum catalyst surface or
on the acid catalyst sites.
Most isomerization reactions, however, occur through formation of a
carbocation.
The formed carbocation could rearrange through a hydride-methide
shift that would lead to branched isomers.
Example: the isomerization of n-heptane to 2-methylhexane through
1,2-methide hydride shifts.

Isomerization of alkylcyclopentanes may also occur on the platinum

catalyst surface
or on the silica/alumina.

3.) Hydrocracking
Hydrocracking is a hydrogen-consuming reaction that leads to higher gas
production and lower liquid yield.
hydrocracking long-chain molecules can produce C6, C7, and C8
hydrocarbons that are suitable for hydrodecyclization to aromatics.

19

Introduction of the unit of Gujarat Refinery:Catalyst Reforming Unit of Gujarat Refinery was designed & commissioned with
Russian collaboration in October 1966. The design capacity of the unit was 3,
00,000 MTPA. Since 1968 BT production also started along with MS. Russian
catalyst was changed over to Engle Hard RD-150/RD-150 C in 1974. Unit was
revamped for production of benzene, toluene & xylene in March 1990. The
reformer catalyst was changed from mono metallic to CK-433 (bimetallic) catalyst.
The new catalyst is very sensitive to the impurities like sulfur, Nitrogen, Water,
Heavy Metals etc.
Naphtha of two cut ranges i.e. 70-900 C and 90-1700 C cut is processes separately
in blocked out operation to produce the reformate specific for Benzene/Toluene
and MS recovery, respectively.
Catalyst used: Platinum and Rhenium supported on high purity alumina.

PROCESS FLOW DESCRIPTION:PRETREATER:The fresh feed naphtha coming from feed tank through the pump is mixed with
the recycle gas. This reactor feed is pre-heated in the feed effluent heat
exchanger and funally heated up to the reaction temperature (305-3350 C) in the
furnace.
Desulfurization and dentirification reaction take place in the reactor. The reactor
effluents are cooled first in the feed effluent exchanger and finally in the water
cooled exchanger.
Liquid and vapor phases are separated in the drum. A part of vapor is purged to
remove light gases from the system and the remaining hydrogen rich stream is
recycled to make up for the loss of hydrogen and to maintain hydrogen partial
pressure at the desired level in the reactor, a certain amount of make up gas is
drawn from the reformer section. The mixture of recycle gas and make up the gas
20

is compressed in the compressor& is added to the fresh naphtha feed. A knock

out drum is provided at the compressor suction to minimize entertainment, of
liquid droplets to compressor suction.
The liquid from the separator is heated by the stripper bottoms in the feed
bottoms exchanger and is fed to remove H2S and other lighter components. Reboiling heat is supplied by a furnace. The overhead vapors from stripper are
cooled in water cooler. The vapor rich in H2 and H2S is sent to the fuel as system.
Any water collected in the boot is drained on level control. The amine is prepared
in a dosing tank and is mixed at the injection point. Normally PH in is maintained
around 6.5.The pretreated naphtha is pumped to the reformer unit after
exchanging heat with the stripper feed in exchanger. Provision is there to send
pre-treated naphtha to slop or storage tank-554 through cooler. Auxiliary systems
provided are facilities to inject Dimethyl disulfide.

REFORMER:
The process sequence with arrangement of process equipment are shown in pr,.
The pre-treated stabilized naphtha is pumped by pumps and mixed with the
recycle gas. The two phase mixture of combined feed enters the shell side of two
heat exchanges working in series and heated by the reactor effluent flowing on
the tube side. Preheated feed then enters convection side of furnace. It then gets
further heated in RAD-2 coil followed by RAD-1 coil where it is heated to a
reaction temp. 0f 501/5060 C in a inter-heater and fed to a second reactor.
In this reactor also outlet temp will drop. Reactor outlet product is again heated
up to reaction temp. inter heater and fed to the reactor R-3 & R-4 working in
parallel.
Part of the reactor effluent from the reactor R-3 & R-4 is sent to the stabilizer reboiler T-8 and again joins the rest of the effluent after exchanging heat in T-8. The
effluent mixture then enters the tube side of T-5/T-4 working in series. The
effluent is further cooled in water cooler T-6 and T-7 in series.
21

The water cooled effluent ex T-7 flows to product separator C-2 where liquid and
gas phase are separated. The gas flows to second separator C-3 where any liquid
carryover is knocked off. Part of the gas from C-3 is diverted to fuel gas,
maintaining system pressure at 16.0 to 18.0 kg/cm2. The rest of the gas is
compresses in recycle gas compressor and recycle back, keeping specified mole
ratio. A part of compressed gas is diverted to pretreater unit as make up gas. The
liquid from separator c-2 is preheated in k-2 feed/ bottom exchanger T-10 and fed
to the stabilizer K-2 reformate is cooled in T-10 and water cooler T-11 and sent to
MS tank in OM&S.

22

Figure: Process Flow diagram of CRU

23

FLUIDIZED CATALYTIC CRACKING (FCC)

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

molecules are decomposed into

small lower boiling molecules. At the time certain of these molecules, which are
reactive, combine with one another to give even larger molecules than those
present in the original stock. The more stable molecules leave the system as
cracked gasoline and reactive ones polymerize forming fuel oil and even coke.
Although primary objective in development of the cracking process had been to
get more and more of gasoline, all other oils having boiling ranges intermediate
between fuel oil and gasoline is also produced. The originally developed process
of cracking was Thermal Cracking. Use of catalyst for cracking was first
24

investigated by HOUDRY in 1927.Catalytic cracking has many advantages over

Thermal cracking viz.
1.

Catalytic cracking gives more stable products.

2.

For corresponding yield and quality of gasoline, catalytic

cracking unit operates under less severe conditions.

3.

Catalytic cracking gives high-octane gasoline (viz.91-94

octane).

4.

It yields less gas viz. Methane, Ethane and Ethylene.

BATCH PROCESS:
The first Commercial Catalytic Cracking Unit was put into operation in 1936. It was
a Fixed-bed Catalytic Cracking Unit. It consists of a series of chamber / reactors,
wherein one of them is on-stream, the others will be in the process of cleaning,
regeneration etc. This type of process has a disadvantage of being an intermittent
process having a high initial investment and operating cost.

CONTINUOUS PROCESS:
The advantages of continuous process led to the development of the idea of a
moving bed catalyst. Examples of this type are Thermofor Cracking; Thermofor
Cat Cracking and Houndry Airlift processes. In the Thermofor Cat cracking, the
Palletized Catalyst was conveyed between the Reactor and regenerator by means
of Bucket Elevators. Higher investment by capacity limitations of Elevators/Air lift
25

systems together with other Engineering and process difficulties led to the
development of latest concept in moving bed catalytic cracking i.e. Fluidized
Catalytic Cracking.

FLUIDIZED CATALYTIC CRACKING:

The radical development was made by Standard Oil Co., New Jersey, M.W.Kellogg
and UOP in early 1940s in which the Catalyst in the form of fine powder was held
in suspension in Gas Stream. It was found that by carefully controlling the Catalyst
particle size and the velocity of gas moving through it, a Fluidized bed of Catalyst
would form which has the properties of liquid. In the fluidized system, finely
Powdered Catalyst is lifted into the Reactor by incoming oil, which immediately
vaporizes upon contact with the Hot Catalyst and after reaction is complete, it is
lifted into the regeneration zone. Cat Crackers using Powdered Catalyst in this
way are known as FLUID CAT CRACKING UNITS.
FEED: - VGO and VR from FPU. The feed is characterized by following:
1).Carbon Residue
Carbon residue of the feed stock is determined by CCR and it indicates the coke
forming tendency to feed. Valued for good cracking feed stock are 0.2 % wt or
less.
2).Metal Content
Most crude oil contain metallic compound which can enter the catalytic cracker
either by entertainment or because the compounds are themselves volatile and
actually distilled in the feed preparation units Ni, Fe, C u are particularly harmful.
Cleanliness of a charge stock with respect to metals is judged by its metal factor.

26

3). Sulphur
It is undesirable in catalytic cracker charge as it is in the feed to any refining unit
since it causes corrosion of the equipment. Also it increases difficulty of treating
products and lower lead response of catalytic cracker gasoline.
Catalytic Cracking Reactions:
Catalytic cracking reaction produce unsaturated short chains like ethylene,
excellent high octane components like benzene ans isooctane and lower
molecular weight gas oil like cetane. During cracking, apart from basic reaction of
breaking of big molecules to small ones, other reaction like isomerization,
cyclization, alkylization, polymerization etc also take place.
Cracking Catalyst:
The catalyst used in catalytic cracking process as a fine powder made up primarily
of alumina and silica. Basically there are two types of catalyst amorphous and
zeolite. Zeolite catalyst contains molecular sieves and varying quantities of rear
earths. These are formed through reaction of reactive forms of alumina and silica.
Products:
The FCC unit catalytically cracks the vacuum gas oil(VGO) from vacuum distillation
unit(VDU) and feed preparation unit (FPU) to various high priced hydrocarbons.
These hydrocarbon vapor are separated by into the following products in the
fractionating and gas concentration section:
a)
b)
c)
d)
e)
f)

Fuel gas
LPG
Gasoline of high octane number
HSD components
LDO
Fuel oil components

27

Process:
FCC consists of three sections:
1) Catalyst section
2) Fractionating section
3) Gas concentration section
Catalyst section:
The Catalyst Section consists of the Reactor and Regenerator, which, together
with the Stand Pipes and Riser, form the Catalyst Circulation System. The
catalyst circulates up the Riser to the Reactor, down through the Stripper to the
Regenerator across the Regenerator Standpipe, and back to the Riser.Fresh feed
and recycle streams, known as Combined Feed, are vaporized and heated to the
reactor temperature by the hot catalyst. This mixture of oil vapour and catalyst
travels up the Riser into the Reactor. The gas oil commences to crack immediately
when it contacts the hot catalyst in the Riser and continues until the oil vapours
are disengaged from the catalyst in the Reactor. The cracked products in the
vapour phase goes from Reactor to the fractionators through Reactor Vapour
line.
Reactor:
The combined feed meets with hot catalyst from regenerator at the bottom of
reactor riser. The resulting catalyst-oil vapour mixture is raised to the desired
reaction temperature by using sensible heat of catalyst. Almost total cracking
reaction takes place in the riser. Residence time in the riser is around 3-5 seconds.
Lift steam is also introduced at the bottom of the riser through flow controller
2FC-7201 and 2FC-7202 to lift the catalyst/oil mixture inside the riser.The oil
28

vapours disengage from the catalyst as soon as they leave the VSS (Vortex
Separator System) and leave the reactor through 3 nos. single stage cyclone
separators suspended from reactor top head. The catalyst from the cyclones
returns to the dense phase of reactor, through cyclone dip legs.

Regenerator:
In the process of cracking in the riser / reactor, coke deposition takes place on the
catalyst surface. With the result, the active surfaces of catalyst reduce. To
regenerate the catalyst, the deposited coke is burnt off by air in the regenerator.
The atmospheric air is taken though a blower, 820-K-01, at ambient conditions
and discharged to the regenerator at 220-250 oC. The excess air is vented to
atmosphere by 2FC 6819. This c/v controls the airflow through regenerator
depending upon the cyclone temperature set in the RMPC. The regenerated
catalyst leaves the regenerator through the regenerator standpipe. A slide valve
(RCSV), which is reset by 2TC 7316, controls the temperature of the reactor. An
expansion joint is provided on this standpipe. The regenerated catalyst goes to
the bottom of the reactor riser and is lifted by the lift steam/ VB naphtha. As the
catalyst rises up the riser it mixes with the combined feed and slurry recycle
streams, which are injected through their respective nozzles. Thus catalyst
circulation is established between reactor and regenerator. Normal catalyst
circulation rate is 16-22 MT/minute.

29

Orifice Chamber:
The coke is burnt in the regenerator to form a mixture of carbon monoxide and
carbon dioxide.The gases containing 6-8 % CO come out of 3 sets of two stage
cyclones in regenerator and leave from the top. A double disc slide valve (DDSV)
located on the flue gas line is reset by 2PDC 7346. DDSV controls the differential
pressure between the regenerator and reactor. Gases are passed through an
orifice chamber, 820-ME-3, where a series of restriction orifices reduce the
pressure of gases so that differential pressure across DDVS is reduced which in
turn reduced its erosion.The two-port slide valve located at the bottom of orifice
chamber routes the flue gases either to CO Boiler or to the stack bypassing CO
Boiler.A sacrificial sleeve is provided on the outlet nozzle or DDSV to protect the
conical portion of orifice chamber from erosion.
CO Boiler:
The Co boiler is just like any other convectional water tube boiler consisting of
two drums and one super heated disposed at the flue gas path. It is a front wall
fired medium pressure (MP) & Temperaure, natural circulation boiler. The upper
drum, which is called stream drum but essentially contains stream and water
both, is fed with hot feed water(132-140 deg. C) supplied through a feed control
valve the colder water from the upper drum flows to lower water drum through a
bunch of a tubes called down comers which are disposed at the lower
temperature zone of the furnace. The water content in the furnace wall tubes or
riser tubes is heated by the heat releases in the furnace on combustion of fuel.
30

The heated water in the riser tubes becomes lighter and moves up into the upper
stream. These riser tubes are disposed in such a fashion that it makes a closed
envelop of the furnace covering all the six sides of the furnace so as to pick up
maximum possible heat.

Fractionation section:
In the fractionation section, the Reactor vapours are fractionated into Wet Gas,
Unstabilized Gasoline, Heavy Naphtha, Light Cycle Oil (LCO), Heavy Cycle Oil (HCO)
and Clarified Oil (CLO).
The reaction product vapors (at 535 C and a pressure of 1.72 barg) flow from the
top of the reactor to the bottom section of the fractionator where they are
distilled into the FCC end products of cracked naphtha fuel oil and offgas. After
further processing for removal of sulfur compounds, the cracked naphtha
becomes a high-octane component of the refinery's blended gasolines.
The main fractionator offgas is sent to what is called a gas recovery unit where it
is separated into butanes, butylenes, propane, and propylene and lower
molecular weight gases (hydrogen, methane, ethylene and ethane). Some FCC gas
recovery units may also separate out some of the ethane and ethylene.
Although the schematic flow diagram above depicts the main fractionator as
having only one sidecut stripper and one fuel oil product, many FCC main
fractionators have two sidecut strippers and produce a light fuel oil and a heavy
fuel oil. Likewise, many FCC main fractionators produce a light cracked naphtha
31

and a heavy cracked naphtha. The terminology light and heavy in this context
refers to the product boiling ranges, with light products having a lower boiling
range than heavy products.
The bottom product oil from the main fractionator contains residual catalyst
particles which were not completely removed by the cyclones in the top of the
reactor. For that reason, the bottom product oil is referred to as a slurry oil. Part
of that slurry oil is recycled back into the main fractionator above the entry point
of the hot reaction product vapors so as to cool and partially condense the
reaction product vapors as they enter the main fractionator. The remainder of the
slurry oil is pumped through a slurry settler. The bottom oil from the slurry settler
contains most of the slurry oil catalyst particles and is recycled back into the
catalyst riser by combining it with the FCC feedstock oil. The so-called clarified
slurry oil or decant oil is withdrawn from the top of slurry settler for use
elsewhere in the refinery, as a heavy fuel oil blending component, or as carbon
black feedstock.

Gas concentration section:

Compressed Wet Gas and Unstabilized Gasoline go to Gas Concentration Unit
where they are separated into Fuel Gas, LPG & Stabilized Gasoline, LPG and
Gasoline are washed with caustic in the treating section of Gas Concentration
Unit. Amine treatment of LPG is done prior to caustic wash.

32

Further Processing of Products:

The main products from FCC unit are gasoline and LPG. After these products are
separated through fractionation and stabilization section, they are given some
chemical treatment like caustic soda and water wash to remove the impurities
still present.
Following chemicals are used in FCC:
1) Caustic soda:
Caustic soda is used for LPG and gasoline caustic wash. It removes H2S and
lighter mercaptans from these streams. Caustic with approximately 40-45 %
strength is received from LPG station through a 2 line into tank. This caustic is
diluted to 10-15 % by adding water to tank.
2) TRI Sodium Poshpate:
Tri-sodium poshhpate is added to MP steam generations. It helps in reducing
scale formation in the steam generation by forming sludge with scale forming
scale forming salts. This sludge goes out of the system during below down
operations.
3) Hydrazine(N2H4) :
While major portion of dissolved oxygen is removed from boiler feed water is
scavenges with the help of hydrazine.
N2H4 + O2

2H2O + N2

33

4) Ahuralan:
It is an organic chemical, which acts as corrosion inhibitor by forming
continuously renewable monomolecular layer in the metal surface with
corrosive elements, present in the system.

Figure: Process Flow Diagram of FCC

34

Oil Movement and Storage (OM&S)

Introduction:The Oil Movement & Storage (OM&S) is a part of Production Department which is
headed by Chief Production Manager. OM&S is supported by Senior Production
Manager.
Receipt:
The objectives and function of OM&S are as follows:Objectives:
01.

02.
03.
04.
05.
06.
07.
08.

To receive crude oil and uninterrupted supply to processing units after

proper accounting and tank operations, in environment friendly manner,
keeping internal customers satisfaction.
To receive intermediates and finished product streams ex units to prepare
quality product in a safe & environment friendly manner.
Timely supplying the quality products to Marketing as per planning and
schedule to meet the market demand.
To meet the statutory requirements of Central Excise & Customs w.r.t.
Crude & Petroleum Products storage and movement.
To maintain safe and pollution free environment. To strive for internal and
external customer satisfaction.
To conserve energy by controlling losses.
To ensure safety of personnel & equipments by adopting safe practices.
To continuously upgrade and assess the knowledge and skills of operating
personnel.

Functions:
1. Receipt, storage, accounting, sampling of crude oil.
2. Crude & LABFS tank preparation and uninterrupted feeding to processing
units.
35

3. Receipt, storage, accounting of finished products and intermediates ex. Units

and blending of intermediates and blending of MS at blending station to make
HIGH QUALITY as EIV MS finished products with minimum quality give away
and to delight customer and to protect environment..
4. Supply of intermediates (feed) to processing units.
5. Preparation of finished products tanks for dispatch. Sampling for Quality
Certificate and accounting.

6. Product dispatch by pipeline, T/W & TTL.

7. Excise & Customs formalities and co-ordination with central excise & custom
officials for carrying out day to day operations.
8. Unloading the rail wagons declared either sick by railway or contaminated by
Marketing.
9. Unloading of Truck of different chemicals. e.g Benzene.
10.Slop recovery and reprocessing to units.
11.Preparation of Tank for cleaning, inspection, repair & maintenance.
12.Co-ordination with Technical Services & Marketing for planning and supply of
finished products.
36

13.Co-ordination with Railway and Marketing for availability and placement of rail
wagons as per planning schedule.
14.Co-ordination with service departments (Maintenance /inspection/ Technical
services) for maintaining good house keeping and health of equipment, gantry
area, and facilities, safe and in healthy condition for operation.
The Oil Movement & Storage Division consists of various sections like

a)

Receipt and Blending

b)

Tank Wagon Handling

c)

Tank Truck Loading

d)

LPG

e)

Bitumen

Storage Tanks:
All petroleum stocks from crude oil to its lightest volatile fraction must be stored
during the intervals between production, transportation, refining, blending and
Marketing. Hence, for this purpose, different types of tanks and vessels to suit the
characteristics of the product to be stored are provided.

37

TYPES OF TANKS:
The storage tanks are mainly of three types.

1.

Cone roof or fixed roof tanks for storing heavy products.

2.

Floating Roof tanks for lighter products.

3.

Floating cum fixed roof tanks.

Less volatile petroleum stocks are stored in Floating Roof tanks, highly volatile
liquids like LPG, 80 MT are stored in pressure vessels like spherical ( horton
sphere) or cylindrical (also known as bullets) Mounded Bullets.
FLOATING ROOF TANKS:
These are vertical cylindrical welded steel tanks with open tops equipped with
Floating Roof which cover and ride up and down, on the liquid stored in the tank.
The Floating Roof reduces evaporation loss.

In Floating Roof tanks also, the following accessories will be found and these are
discussed in detail in the preceding pages.

Tank pad

Tank insulation

Steam coils

Inlet, outlet and Mixer nozzles

Staircase

Reference height

38

Earthing

Lightening arrestor

Dykes

Open surface drains

Swing arm

Tank mixers

Side mixer

Jet mixer

TYPES OF FLOATING ROOFS:

There are three types of Floating Roofs:

1.

Pan Type

2.

Pontoon Type

3.

Double deck type

Here, only one type (pontoon type) is discussed in details.

39

PONTOON TYPE:
The roof has an annular pontoon around the outer edge of the roof and a deck of
single thickness at the center. The top of the pontoon is sloped downwards to the
center of the tank. In addition to buoyancy the pontoons provide air-space
insulation from the suns heat, thus reducing evaporation losses. The pontoon is
divided into several compartments with redial bulkheads, which allow the roof to
remain afloat even if the center deck or any of the compartments develop
leakage. Each compartment is provided with a manhole or inspection hatch. In
some cases, the cover is bolted while in others, loose covers are provided.

Dispatch:
For efficient functioning of the refinery one of the major factors is to regulate off
take movement of products.Since large volumes of high priced products are
involved, utmost care is called for in handling of products during despatch.
Despatch of products by the different modes depending upon a number of factors
like market requirement, product availability etc. is an important exercise for the
Oil Movement and Storage Section. To achieve the smooth functioning of
despatch systems a close co-ordination between Marketing, Railways and other
agencies involved in the process is called for.
A product becomes ready for despatch only after getting the quality certificate
from laboratory and after complying with the necessary excise formalities.
There are three modes of transport operating in this refinery for the despatch of
products.
They are:
Pipeline
Road
Rail.
40

41