A Vocational Training Report On

Overview Of Old Unit

INDIAN OIL CORPORATION LIMITED

Mathura Refinery Mathura (U.P.)

Submitted by:TANUJ GUPTA Chemical Engineering Hindustan College Of Science & Technolog Roll No.-0806451072

ACKNOWLEDGEMENT
I, TANUJ GUPTA pleased to submit my training report which I have been able to complete after closely studying the various operations at Indian Oil Corporation Limited Mathura Refinery, Mathura. I am highly grateful to Mr. R. K. Prasad, Chief Manager (MS & Training) and Mr. S. Debnath (Chief Technical Services Manager) for their guidance & cooperation. I also heartily thank all the Unit Heads and all technical & Non-Technical staff of MATHURA REFINERY for their great effort to enhance my practical knowledge. I can say that the plant training will surely enhance my capabilities to perform better in my future.

CERTIFICATE
This is to certify that TANUJ GUPTA a student of Chemical Engineering (Hindustan College of Science & Technology, Farah) has completed his summer vocational training with our organization for a period of one month, starting from 1/07/2011 to 31/07/2011.

(Mr. R. K. Prasad) Chief Manager (MS & Training)

ABOUT INDIAN OIL CORPORATION LIMITED

Incorporated in 1959, Indian oil Corporation Limited is a wholly government owned company registered under the companies Act 1956. It came to existence on 1st September 1964 as a result of amalgamation of the erstwhile Indian Refineries Ltd and Indian Oil Company and has its registered office at Mumbai. The corporation is managed by board of directors. The Indian Oil Corporation has five Divisions, namely (i) (iii) (v) Refinery Division Pipe Lines Division Assam Oil Division (ii) Marketing Division (iv) R&D Centre and

Each Division is headed by Director (Refinery) Director (Marketing) Director (Pipe Line) and Director (R&D) respectively. The Refinery Division is mainly concerned with the setting up and operation of refinery and petrochemicals in India. It owns and operates seven refineries; at Guwahati (Assam), Barauni (Bihar), Vadodara (Gujrat), Haldia (West Bengal), Mathura (Uttar Pradesh), Panipat (Haryana). The Assam Oil Division has one refinery at Digboi.

ABOUT MATHURA REFINERY

Mathura Refinery, commissioned in 1982, presently operates at 8.0 MMTPA crude processing level and is meeting the product demand of north-west region of the country including the national capital Delhi. The Refinery processes low sulfur crudes from Bombay High and Nigeria and high sulfur crudes from Middle East Countries. The process configuration of the Refinery employs the state of the art technologies with minimum impact on the environment. Various steps have been taken by Matura Refinery to monitor and control the emission of sulphur dioxide. Mathura Refinery is the only Refinery in the country to setup the Concern of community and Archeological sites. Mathura Refinery has taken extra-ordinary initiatives to provide green cover to the archeological heritage sites specially the Taj Mahal by planting 1,15,000 trees in the Taj Region.

REFINERY
A refinery is a production facility composed of a group of chemical engineering unit processes and unit operations used for refining certain materials or converting raw material into products of value. An oil refinery is an industrial process plant where crude oil is processed and refined into more useful petroleum products, such as gasoline, diesel fuel, asphalt base, kerosene, and liquefied petroleum gas.

Composition of Crude Oil

Crude oil is a complex mixture of thousands of hydrocarbons. (i.e paraffins, napthenes & aromatics). It is brownish black in colour and colloidal in nature. It contains small amounts of non-hydrocarbon impurities in the form of organic compounds of sulphur, oxygen, nitrogen, metals, water and salts.

Physical and Chemical Processes

ATMOSPHERIC-VACUUM DISTILLATION UNIT (AVU)

AVU consists of following sections: Crude Desalting section Atmospheric Distillation section Stabilizer section Vacuum Distillation section

PROCESS FLOW DESCRIPTION

FEED SUPPLY Crude oil is stored in eight storage tanks (eight tanks each having a nominal capacity of 50,000 m3 whereas remaining other 2 tanks are of 65,000 m3 nominal capacity). Booster pumps located in the off-sites are used to deliver crude to the unit feed pumps. Filters are installed on the suction manifold of crude pumps to trap foreign matter. For processing slop, pumps are located in the off-site area, which regulate the quantity of slop into the crude header after filters. Provision to inject proportionated quantity of demulsifier into the unit crude pumps suction header with the help of dosing pump is available.

SYSTEM DESCRIPTION: Before treating the crude it is necessary that the salts and sediments from it be removed because the hydrolysis of salts in crude oil at high

temperature produces hydrochloric acid which corrodes the Column Internals and overhead system. The sediments in crude oil foul the heat exchanger, furnace tubes and erode the pipelines by abrasive action. Desalting approaches to reduce soluble salt content, to reduce suspended solids and to reduce residual water. Desalting of crude oil is carried out in a vessel provided with electrodes under high potential field(15000-18000 Volts) Desalter Operating condition: -Temperature range :130-140 deg C -System pressure :12-14 kg/cm2g Provision to use DM water/ services water is also provided. from the 1st stage desalter is sent to ETP on level control. The crude after leaving the desalter is preheated to 250 to 265 C. The preheated crude is further heated and partially vaporized in Atmospheric Furnace (four furnaces with four pass each). CRUDE DISTILLATION UNIT : The column is provided with 56 trays of which 8 are baffle trays in the stripping section. Heated and partly vaporized crude feed coming from fired heater enters the flash zone of the column at tray no. 46 at 355 C/365 C.Hydrocarbon vapors flash in this zone and get liberated. Nonflashed liquid moves down which is largely bottom product, called RCO. Reduced crude oil product is collected at the bottom of the column and the overhead vapors are totally condensed in Overhead air Condenser and train condenser. This condensed overhead product is separated as hydrocarbon and water in the reflux drum. Water is drawn out under inter-phase level control and sent to sour water drums. VACUUM DISTILLATION UNIT : The electric field in the desalter breaks the emulsion and the outlet brine

Hot RCO from the atmospheric column bottom at 355 C is mixed with slop recycle from Vacuum Column, heated and partially vaporized in 8-pass vacuum furnace and introduced to the flash zone of the vacuum column. The flash zone pressure is maintained at 115-120 mm of Hg. Steam (MP) is injected into individual passes and regulated manually. Three injection points have been provided on each pass. This is to maintain required velocities in the heater, which is Fuel Gas, Fuel Oil or combination fuel fired. Each cell is provided with 10 burners fired vertically upshot from furnace floor along the centerline of the cell. The vaporized portions entering the flash zone of the column along with stripped light ends from the bottoms rise up in the vacuum column and is fractionated into four side stream products in 5 packed sections. The hydrocarbon vapors are condensed in the Vac Slop, HVGO, LDO and LVGO sections by circulating refluxes to yield the side draw products. Vacuum is maintained by a two-stage ejector system with surface condensers. The condensed portion from the condensers are routed to the hot well from where the non-condensable are sent to the vacuum furnace low-pressure burners or vented to the atmosphere.

SIGNIFICANCE OF VDU
1.RCO from CDU is heavy, and the separation of this stream into various fractions would normally require more energy and higher temperatures. Also higher hydrocarbons promotes coking reactions at more than 380 deg c at atmospheric pressure fouls the furnace tubes. 2.To reduce the amount of energy input required, and to recover the valuable products from RCO without cracking, it is distilled under vacuum. 3.The vacuum condition reduces the boiling point of the RCO and the fractions are separated relatively at lower

temperature which lead to energy saving and reduces fouling ofthe furnace tubes

VISBREAKER UNIT
The Visbreaker Unit is a thermal cracking unit, designed for processing a mixture of Atmospheric and Vacuum Residue from 1:1 mixture of Light Arabian and North Rumila crudes .It reduces the viscosity and pour point of heavy petroleum fractions so that product can be sold as fuel oil. It reduces the viscosity and pour point of heavy petroleum fractions so that product can be sold as fuel oil. The design capacity of the plant is 1000,000 TPA.

THEORY OF VISBREAKING
The Visbreaker is essentially a Thermal cracking unit designed to operate at mild conditions and to retain all the cracked light oils in the bottom product. This results in reduction of viscosity of bottom product. In the Thermalcracking reaction, heavy oil is kept at a high temperature of a certain amount of time and this causes the larger molecules to break up. The resulting product has a random distribution of molecular sizes resulting in products ranging from light gas to heavy gas oil. These products are characterised as "Cracked" products and contain a certain percentage of olefinic compounds. Whenever a molecule breaks one of the resulting molecules is an olefin. CH3-CH2-CH2-CH2-CH2-CH2-CH3 CH3-CH2-CH=CH2 + CH3CH2-CH3

During the cracking operation, some coke is usually formed. Coke is the end product of polymerisation reaction in which two large olefin molecules combine to form an even larger olefinic molecule. When above reaction gets repeated several times, the end product is coke. This is usually found inside the walls of furnace tubes and other spots where oil may remain at high temperature and soak heat for some time. Severity of over-all reaction is determined by residence time and temperature of cracking. Residence time in the unit can be varied by varying charge rate and steam injection rate of DMW injection into furnace coils. Temperature can be varied as per requirement. The cracking reaction usually does not become evident until transfer temperature crosses 400 C. When transfer temperature reaches 460 C; sufficient cracking of oil takes place. Gas and Naphtha are produced, the viscosity of product is lowered and simultaneously coke deposits in the furnace tubes & soaker. Increased severity results in shorter run lengths and more unstable fuel oil with sediments in it.

V.B. FRACTIONATOR
Soaker effluent after quenching enters fractionator. Temperature in the flash zone is around 420 (C. From the column, gas & gasoline are separated as overhead, gas oil as side stream and the VB tar as bottoms. The fractionator has 26 valve trays and one blind tray. Feed enters flash zone below the 26th Valve tray. The overhead vapours from the column are condensed and cooled in heat exchangers. The liquid vapour mixture is separated in the reflux drum. Gasoline from flash fractionator is picked up by reflux pumps and partly pumped to column top as reflux. The remaining gasoline is routed to stabiliser under reflux drum level controller, which is cascaded with flow controller. The sour water is drained from the drum boot under interface level controller and routed to sour water stripper. Main reflux drum and its water boot are having level glasses. Uncondensed gas from Gas oil stripper goes to FCC/AVU furnaces / Flare. Column top

pressure around 4.5 kg/cm2 (g). Column overhead line is provided with working and controlled safety valves. The heavy naphtha at a temperature of about 170 (C is withdrawn from tray no. 10 under level controller. It is stripped in the stripper to maintain its flash point. The heavy naphtha is routed to HSD. Gas oil at a temperature of about 260 (C is withdrawn from the blind accumulator tray under tray level controller. It is steam stripped in the stripper to maintain its flash point. Vapour from stripper top returns back to column just above the blind accumulator tray. . A part of gas oil from air cooler is used for washing VB tar filters. Blind accumulator tray and stripper are provided with level glasses To remove extra heat and to maintain desired temperature profile in column, a portion of gas oil from blind tray is taken and pumped in two streams. One stream is used as heating media in steam generator where it is cooled from 260 (C to 214 (C. The second stream supplies reboiling heat to stabiliser re-boiler and gets cooled from 260 (C to 215 (C. To protect column bottom against coking, cooled VB tar at 225 ( C is injected into bottom as quench. Gas oil vapours from top of stripper get condensed in air cooler and go to reflux drum. Safety valve is provided to release gas and protect the vessel from over pressure. Tar is cooled from 351 (C to 225 (C in feed exchangers and further cooling to 214 (C is done. Pumps are having two filters in the suction line with gas oil flushing facilities. Only one filter is kept in service while the other remains as spare VB tar is then cooled in boiler feed water exchanger from 2320 C to 2100 C. It is further cooled to 900 C and sent to storage with gas oil.

STABILISER
Un-stabilised gasoline from reflux drum is picked up by reflux pump and then it is pumped to stabiliser through stabilised gasoline exchanger. In heat exchanger, feed is heated from 43 (C to 120 (C while

stabilised gasoline is cooled from 180 (C to 120(C. The column has 30 trays and the feed enters on the 19th. The overhead product at 60 (C goes to water condensers. The condensed liquid is collected in the reflux drum. Uncondensed gas from the drum goes to FCC/unit fuel gas header. Pressure at the drum is maintained around 8.4 kg/cm2 (g). In case FCC is shutdown, gas is burnt in furnaces via gas knock out drum. Column overhead has

working and controlled safety valves, which release gas.

VBU PRODUCT YIELD

FLUIDISED CATALYTIC CRACKING UNIT (FCCU):INTRODUCTION

Fluidised catalytic cracking is a process for converting higher molecular weight hydrocarbons into lighter, most valuable product through contact with a powdered catalyst at appropriate process conditions. Typically FCC process is used to convert excess refinery gas oil & heavier refinery stream into gasoline, C3 & C4, olefins and light cycle oil bringing the Refinery out more in line with product market demand. FCC is often the heart of a modern refinery because of its adaptability to changing feed stocks and product demands and because of the high margin that exists between FCC feed stock and converted FCC products. PROCESS DETAILS:DESIGN CAPACITY CAPACITY AFTER REVAMP (2000) I.O MMTPA 1.34 MMTPA

DESIGNED

HVGO (Heavy Vacuum Gas oil) derived from light Arabian and north Rumalia crude.

PROCESSED FEED

MIXED

H.V.G.O(Derived

from

BH(Bombay high), NIGERIAN & HS (high sulfur) ARAB Mix PRESENT FEED HVGO CRUDE DESIGN PACKAGE M/S UNIVERSAL OIL PRODUCT CO. U.S.A. (U.O.P.) derived from NIGERIAN

YEAR OF COMMISSIONING

28/01/1983

PROCESS DESCRIPTION

(A) FEED & PRE HEAT SECTION:(1) HVGO Feed is received in feed surge drum (19V-4) from three different sources, viz., from feed tanks in cold feed, directly from VDU (Vacuum Distillation Unit) as hot feed and directly from Hydro cracker Unit. (2) Hot feed from VDU and OHCU is received directly in 19V-4. (3) Balance amount of feed is fed by pumps at OM&S and received in 19V-4 (vessel) through 19 FRC-118, which can be cascaded with 19V-4 level controller in 19 LRC 121. (4) From Feed surge drum (19V-4), feed is pumped by 19P-2A/B feed pumps through pre heat exchanger train. Flow to both trains is regulated by 19FRC-292A/B. (5) Pre heated feed (275 310oC) is pumped by booster pumps 19P-25 A/B and made to pass through 19F-1 (Furnace) into passes where it is heated up to 355 360oC. (6) Pre heated feed injected to reactor riser at the bottom through 4 Nos nozzles. (B) REACTOR SECTION 1- At riser bottom feed comes in contact with hot stream of regenerated catalyst and cracking starts occurring. Flow of hot catalyst is regulated by slide value in order to control reactor temperature. 2- HCO and slurry recycles are injected into riser through 2 Nos Nozzle. Each of spray nozzle is at two different elevations. 3- The cracking reactions are endothermic. Coke generated in the cracking reaction gets deposited on the surface of the catalyst particles and thus the catalyst activity gets reduced. 4- The catalyst gets separated from cracked and uncracked HC vapours and steam at riser termination and then at reactor cyclones.

(C) REGENERATOR SECTION:-

1- The spent catalyst gets accumulated at reactor stripper and HC vapour enters 19C-1 for fractionation. 2- Oxidation of coke is highly exothermic reaction and it provides the necessary heat to reactor for reaction in such a way that the unit remains in heat balance always. 3- Flue gases rich in CO pass through CO-boiler where CO is burnt and generated heat is used for steam production.

(D) FRACTIONATOR SECTION:1- The super heated vapours from reactor enters 19C-1 below the bottom most tray and is cooled down to 360oc for fractionation. Main column bottom (MCB) is circulated back to column through two sets of exchanger (19 E-3 A/B/C/D, 19D-4 & 19 E -21) to de-super heat the vapour coming from reactor. 2- A stream of MCB is taken to 19V-3 slurry settler where catalyst gets settled at circulating reflux after supplying heat to reboiler 20 E-7 of stripper bottom and exchanging heat with raw oil in 19-E-17. A stream of LCO is used as an absorbent in 20C-2 & is also returned back to 19C-1 with other LCO reflux streams. 3- The de-super heated vapour rise up in the fractionation column. The first fraction accumulated in draw off tray is HCO. The Heavy cycle oil circulating reflux transfers its heat to 20C-4 bottom in reboiler 20 E-12 and in steam generator drum 19E-7 and in 19E-2 with raw oil. A part of the HCO is recycled back to riser at HCO nozzle & a stream injected at 19V-3 bottom cone to dilute the catalyst mixed slurry. 4- LCO drawn from accumulator below 19th tray is sent back to column as a reflux. 5- Heavy naphtha cut is drawn from accumulator below 2nd packing and return back to column as a circulating reflux for the heat balance after exchanging heat is 18E-21 with hot water and in 19E-15 with raw oil. Return stream after passing 18E-21 & 19E-15 further can be cooled in air coolers on requirement.

6- A part of LCO & heavy naphtha draws are stripped in 19C-2& 19C-3 respectively and routed to product tanks after exchanging heat in PRU and cooling as diesel component. 7- Overhead vapours from the top of column pass through air coolers 19 E 13 A/B/C/D.

(E) GAS CONCENTRATION UNIT

1- Some amount of liquid from 19 V-5 is pumped back to column as reflux to control the 19 C-1 temperature and balance amount of net over head liquid is pumped out to 20 C-1. 2- Uncondensed vapours from 19 V-5 are sucked and compressed by WGC, cooled and liquid is collected in HP receiver 20 V-3. 3- Liquid from 20 V-3 is fed to stripper where it is heated in 20E-8 & 20E7 to strip out hydrogen sulfide, methane and ethane etc. before sending to debutanizer for stabilization. 4- Stripped gases from 20C-3 top combined with WGC discharge, 20C-1 bottom liquid & 20V-1 bottom stream are cooled down to recover LPG. 5- Gases and H2S pass through absorber for the recovery of LPG & Gasoline and finally routed to refinery fuel gas system after H2S absorption in 20C-6. 6- 20C-3 bottom material in fed to 20C-4 where it is separated into LPG & Gasoline. 7- LPG is routed to merox unit for H2S and mercaptans removal. 8- Gasoline is routed to Gasoline splitter unit for preparation of MSQU feed. Top and bottom material of GSU is routed to merox for mercaptans to disulphide oil.

FCC Feed Characterization

FCC feed characterization is one of the most important requirements of catalyst cracking. Understanding feed properties and knowing their impact on unit performance is essential in anything that has to do with FCC operation including troubleshooting, catalyst selection, unit optimization and subsequent process evaluation. Feed characterization is a means of relating feed quality to product yield and quality. Knowing the effect of a feed stock on unit yields, a refinery can purchase the feed stock that would maximize profitability. It is not uncommon for many refineries to purchase raw oil (crude oil or FCC feed stock) without knowing their impact on unit operation At times, this lack of knowledge can cause unit shutdowns for several weeks. The two primary factors that affect feed quality are: 1- Hydrocarbon calcification 2- Impurities

Important Reaction occurring in FCC.

1- Cracking Paraffins cracked to C10 H22 C4H10 + C6H12 C4H8 + C5H10 olefins and smaller paraffins. Olefins cracked to smaller olefins C9H18 Aromatic Side chain scission ArC5H9+C5H12 Napthenes (Cyclo paraffins) C4H8 cracked to olefins and smaller ring compounds. 2- Isomerization Olefin bond Shift Normal olefins to ISO olefins C4H10 Normal paraffins to ISO paraffins C4H10 n C4H10 ISO 1-C4H8 n C5H10 trans -2- C4H8 ISO Cyclo C10H20 C6H12 + ArC10H21

Cyclohexane to cyclopentane H9 + CH3 3-Hydrogen transfer Napathene + olefin Cyclo-Aromalization

C6H12

C5

Aromatic + Paraffin C6H12 + 3C5H10 C6H6 + 3C5H12 2C6H5CH3

4-Trans-Alkylaltion / alkyl group Transfer C6H4 (CH3)2 + C6H6 5-Cyclization of olefins to Napthenes C7H14 6- Dehydrogenation n C8H18 7- Dealkylation Iso-C3H7 C6H5 8- Condensation Arch = CH2 + R1CH = CHR2 Ar Ar +2H C6H6 + C3H6 C8H16 + H2 CH3 cyclo C6H11

Mass Balance
One of the main object of performing a mass balance is to determine directly or indirectly the composition of product leaving the reactor. The reactor effluent vapours entering the main fractination column are hydrocarbons, steam and insert gas. By weight the hydrocarbons in the reactor over head stream are equal to the fresh feed minus the portion of the feed that has been converted to coke. This is true assuming that no recycle is processed to the reactor if there is a recycle stream its amount should be included with reactor effluent stream. A complete set of data collection should be carried out weekly this will permit distinction between the effect of feed stock catalyst and operating condition on unit performance. An accurate assessment of a catalyst cracking operation require reliable plant data. A reasonable weight balance should hence at least a 98% - 102% closure. Any weight balance exercise the first step is to identify the input and output streams. The sources of steam in the

reactor vapour are lift dispersion, dome stripping and other miscellaneous steam to the Reactor. Depending on the reactor pressure approximately 25% to 50% of stripping steam is entrained with the spent catalyst flowing to the regenerator. Inert gases such as nitrogen and carbon dioxide are entrained with regenerator catalyst. The quantity of these insert gas is related directly to catalyst circulation rate. These gases flow through the gas plant and leave the unit with the off gas (sponge gases) from the sponge oil absorber column. FCC products are commonly reported on an inert free basis as the volume and weight fraction of the fresh feed. Additionally gasoline, light cyclic oil and conversion are reported on a fixed basis such as true boiling point (TBP) cut point are (225oc) TBP end point for gasoline and 343oc (TBP)end point for LCO. The classic definition of conversion is the volume or weight % of feed stock converted to gasoline and other product lighter than gasoline. This excludes coke yield. Conversion is calculated by Conversion % = feed (LCO + heavy cycle oil (HN) + LPG + Gasoline Feed It is necessary to distinguish between the apparent and true conversion. The apparent conversion is calculated before the gasoline cut point adjustment is made and the true conversion is calculated after the cut point adjusted. Mass balance calculation:1- The orifice plate meter factor should be adjusted for actual operating parameter for liquid streams. The flow meters should be adjusted for API gravity, temperature and viscosity. For gas streams the flow rate should be adjusted for the operating temperature, pressure and molecular weight. 2- It is necessary to ensure that the chromatograph analysis of each streams are normalized to 100%

3- By using air rate and flue gas composition the coke yield should be calculated. 4- The flow rate of each stream should be converted to the unit of weight. 5- The quantity of insert gases and extra streams should be subtracted from the FCC gas plant products. 6- After calculation the overall mass balances error. The feed/product should mass balance either by redistributing the error in proportion to their ratio or adjusting a known inaccurate meters. 7- The actual gasoline and LCO cut point should be converted to standard cut points. 8- Using the feed characteristic correlation Analysis of Result :1- The performance of the catalyst cracker in regard to yield and quality of the desired product should be assumed. 2- The result of this test run should be compared with the previous test runs any significant charge in the yield and / or operating parameters should be highlighted. 3- The final step is to perform simple economics of the unit operation and make recommendation than improved unit operation short and long term. Operating Data Fresh feed Rate Sponge gases (off gases) LPG Gasoline H.N. LCO CLO Other pertinent flow Rate := = = = = = = 190 m3/hr 4000 m3/hr 37.4m3/hr 88.0 m3/hr 44.0 m3/hr 23.0 m3/hr 20.0 m3/hr discussed later, composition of fresh feed stock can be determined.

Emergency riser steam Wye steam Fresh feed injection steam nozzle

= = =

770 Kg/ hr 130.88 Kg/ hr 4693.16 Kg/ hr 258.02 Kg/ hr 552.56 Kg/ hr 1.81 Ton/ hr 280 Kg / hr 2991.02 Kgmoles / hr 350.40 0C 494 C 230 0C 670 0C O2 CO N2 = = = 1.8 6.4 8.6 83.2 mol % or vol%

HCO recycle dispersion steam = Slurry recycle dispersion steam = Reactor stripper steam Pre-stripping steam Air to Regenerator Temperature 0C Riser Inlet Riser outlet Air inlet Regenerator Dense bed Flue gas Analysis mol % = = = = = = = =

CO2 = Miscellaneous Data Relation humidity = Fresh Catalyst make up Case Study 45% = 1 ton/day

A test run is conducted to evaluate, performance of 190 m3/hr FCC unit. The feed to the unit is heavy vacuum gas oil (HVGO) from the vacuum unit. No recycle stream is prepared, however the off gas from column is sent to gas concentration unit from the units are fuel gas, LPG, gasoline, LCO, Heavy naphtha and CLO. It is assumed that the meter factor have been adjusted for actual operating conditions.

The sequence of steps to perform the mass balance is as following

1- Identification of the input and output stream used in the overall mass balance equation. 2- Calculation of coke yield 3- Conversion of appropriate flow rates to the unit of mass e.g. lb / hr. 4- Normalization of the data to obtained a 100% weight balance. 5- Determination of the component yield. Input and output streams The input is fresh feed and the output stream is FCC sponge gas, LPG, gasoline, LCO, heavy naphtha, CLO and coke. Coke yield Calculation A portion of feed is converted into coke in the reactor. This coke is carried into the regenerator with the spent catalyst. The composition of the coke products is H2O, CO and CO2. To determine coke yield, the amount of dry air to the regenerator and analysis of flue gas are needed. It is essential to have an accurate analysis of the flue gas. The hydrocarbon content of coke is related to the amount of the hydrocarbons vapour carried over with the spent catalyst into the regenerator and is an indication of the reactor stripper performance. Determination of the FCC unit coke yield Given wet air Relative humidity Ambient temp Dry air Flow: RH= 100*(amount of water vapour present in air)/(amount of water vapour present in saturated air at the given temperature) S= Saturated vapour Pressure = 7778.0269 Pa = 3500.112 Pa Amount of water vapour present in air = 3500.112/101325*2991.02 Partial pressure of water vapour present in air = 0.45*7778.0269 = 2991.02 Kgmol /hr = 45% = 410C

= 103.32 kgmol/hr Therefore, amount of dry air = 2991.02-103.32 = 2887.7 kgmol/hr Flue gas Rate (Dry basis) = = air and Flue gas respectively. The flow rates of each component in the flue gas stream are O2 = = = CO = = = CO2 = = (N2) = = = 1.8 x 2741.92Kg mol / hr 100 49.35 Kg mol / hr 1579.2 Kg /hr 6.4 x 2741.92 100 175.48 Kg mol / hr 4913.44 Kg / hr 8.6 x 2741.92 100 10375.2 kg / hr 83.20 x 2741.92 100 2281.28 kgmol / hr 63875.84 kg / hr = 235.8 Kgmol/hr 2887.7 kg mol/hr x .79 .832 2741.92 kg mol / hr Here .79 and .832 are concentration of Nitrogen in atmosphere dry

An oxygen balance can be used to calculated water formed by composition of coke, O2 balance: O2 In O2 out 2H2 + O2 O2 in = O2 O2 out = = = Kg mol / hr 2 H2 O .21 x (2741.92) 606.415 kgmol / hr 49.35 + (175.48/2) + 235.8 372.89 kgmol/hr = O2 in O2 out

O2 used in combustion

= = O2 consumed water H2O Formed = = calculated as: Carbon = = = = Hydrogen in coke Coke yield Coke yield

606.415 372.89 233.525 Kg mol / hr = 233.525 kgmol / hr

Since for each mol of O2, two mol of water formed, the amount of H2 in coke 233.525 x 2 = 467.05 kgmol/hr

Component of coke are carbon, hydrogen and their rate are C in CO + C in CO2 411.28 kgmol / hr 4935.36 kg / hr 4.935 MT / hr = = = = Air to coke ratio wt/wt Coke yield by wt % 467.05 kgmol / hr 4935.36 + (467.05 x 2) (Kg / hr) 5869.46 kg/ hr 5.869 MT / hr = = 14.78 3.47 %

OVERALL MASS BALANCE Fresh Feed = = = = F G (Fuel gas) = = = LPG Gasoline = = = = 190 m3 / hr, S.G. = 0.89 gm/cc 190 x .89 169100 kg / hr 169.1 MT / hr 4000 m3 / hr ,S.G. = .0011 gm/cc 4000 x .0011 4.4. MT / hr 37.4 m3 / hr r 20.57 MT/hr 88 m3/hr 61.6 MT / hr S.G. = .70 S.G. = .55

Heavy Naphtha (H.N.) LCO = = CLO Mass Balances = = =

= =

44 m3 / hr S.G. =.84 36.96 MT/hr S.G. = .90

23 m3 /hr, 20.7 MT/hr 20.0 m3 / hr 19 MT / hr

S.G. =.95

Fresh feed In (Product + Coke) - Coke

Fresh feed Product (F.G., LPG, gasoline, HN, LCO, and CLO) = = 169.1 (163.19+ 5.87) 0.04 0.0024 % = = = = = = = 2.60 % 12.16 % 36.42 % 21.87 % 12.24% 11.24%

Difference = FG LPG Gasoline LCO CLO Coke Total

Feed Analysis (by weight)

Heavy Naphtha =

3.47 % 99.89 %( By weight)

Normalization of Data By calculation a Preliminaries weight balance seldom has a 100% closure. It is necessary to normalize yield to obtain a 100% weight Balance. For normalize 12FG LPG = = 2.6 x 100 99.89 12.16 x 100 99.89 = 12.173% (By weight) = 2.603 %( By weight)

34567-

Gasoline

36.42 x 100 99.89 21.87x 100 99.89 12.24 x 100 99.89 11.24 x 100 99.89

= = = =

36.46 % (By weight) 21.894% (By weight) 12.253% (By weight) 11.147% (By weight)

Heavy Naphtha = LCO CLO Coke Total = = = =

3.47% (By weight) 100.0 %

HEAT BALANCE
A catalytic cracker continuously adjusts itself to study in heat balance. This means that the reactor and regenerator heat flow must be equal. The regenerator unit burns enough coke to provide energy to 1- Increase the temperature of fresh feed, recycle and atomising steam from this pre-heated state to reactor temperature. 2- Provide the endothermic heat of cracking. 3- Increases the temperature of the combustion air from the air blower discharge temperature to the regenerator flue gas temperature. 4- Make up for heat losses from the reactor and regenerator to surroundings. Heat balance can be performed around the reactor, around the regenerator and as over all heat balance around the ReactorRegenerator. The regenerator heat balance can be used to calculate catalyst circulation ratio and thus catalyst to oil ratio.

Regenerator Heat Balance Calculations Total Heat in : Heat carried by (spent catalyst + coke deposited on catalyst + heat of reaction + air ) Coke yield x Cp x (ROT Datum temp) Cat. Circulation Rate x Cp x (ROT Datum temp)

Regenerator
Combustion of coke

Air flow Rate x Cp of Air x (MAB Discharge Temp. Datum temp)

Total Heat out from regenerator Flue gas enthalpy difference

Radiation Loss (4% of combustion)

Regenerator
Coke desorption = coke yield x desorption rate

Cat.circulaion rate x Cp (Dense phase temp of reg. Datum temp) Heat in Step 1 Coke combustion CO ; H= 0.105 MBtu/kgmol CO2 ; H=0.373 MBtu/kgmol H2O; H=0.229 MBtu/kgmol C + O2 C + O2 H2 + O2

Total heat librated in coke combustion; =(0.105*175.48)+(0.373*235.8)+(0.229*467.05) =213.33 MBtu/hr Step 2 ROT = 4940C = 921.20F Let Datum temperature = 250C = 770F T = Reactor temp Datum temp = coke yield = = Cp of coke = 0.5 Btu/lb0F Heat content Of coke Step 3 Heat content of spent Catalyst Cp of spent catalyst= .236 Btu/lb0F Heat content of spent catalyst= CCR x .236 x (921.2-77) = Step 4 199.2312 x CCR MBTU/ hr Heat content of Air = 230 0C = 4460F = 2887.696 kgmol/hr = 1859.76 kg = 5.462 MBtu/hr 5869.46 Kg/hr 12939.726 lb / hr Mass of coke Coke heat content

Cp of dry air= 0.05 Btu/mol0F Blower Discharge Average temp Air to regenerator Water vapor accompanying air Heat content of Air Total Heat in Step 1

Enthalpy of water vapor accompanying air = 2764.867 Btu/kg =2887.696 * 0.05*(446-77) + 1859.76*2764.867 =58.42 MBtu/h =277.215 +199.23 x CCR (A) Regenerator Heat out Heat content of flue gas = = 6850C 1265oF Avg. temp of F G

F G Component Component O2 CO2 H2O N2 CO Step 2 kgmol/hr 49.35 235.8 467.05 2281.28 175.48 Radiation and Miscellaneous = 4% heat of combustion = 8.53 MBTU/hr Step 3 Heat of coke desorption Coke to Reg. x Cp heat of coke 12939.726 x .00145 (MBTU/hr) = Step 4 18.763 MBtu/hr Heat content of Regenerated catalyst BTU/kgmoles0F 16.78 24.71 19.51 17.17 16.18

Total heat out with flue gas = 71.03 MBTU/hr

T x CCR x Cp of coke Cp = .247 BTU/lb0F T = Regenerator dence bed temp Datum temp = T = = = 1233-77 11560F 286.767 x CCR MBTU/hr

Heat Content of Reg. Catalyst (Equilibrium catalyst) Total heat out from Regerator 89.793+ CCR x 286.767 MBTU/hr--------------(B) Total of heat out (B) 89.793+ CCR x 286.767 922.8 MT/hr 922.8 = Heat Balance in Regenerator Total of Heat in = (A) 277.215 +199.23 x CCR = CCR CAT

Ratio = Oil 169.1

5.46

Heat content of reg catalyst (equilibrium catalyst) = = Total heat in Total heat out 583.396 MBTU/hr 405.314 MBTU/hr = = 277.215 + 363.57 = 682.53 89.793+ 583.396 = 682.53 Heat content of spent catalyst

Reactor Heat Balance Calculation Block diagram Let Datum Temp =00C Total Heat in
Regenerator catalyst heat content = CCR x Cp x T T = (Dense bed temp. Datum Temp)

Feed heat = Feed flow Rate x Enthalpy in = flow rate x H

Reactor

Coke adsorption (Same as desorption) HCO = m x Cp x T = flow rate x H Slurry = m x Cp x T = Flow Rate x H

Recycle Heat Content of Steam = mCp T = Flow Rate x H

Total Heat out

Reactor Vapour = Enthalpy vapor x Feed Flow Rate + Enthalpy Change x HCO Flow Rate + Enthalpy Change x Slurry Flow Rate

Steam Out = mCp x T or m x Enthalpy of Steam at Reactor temp (4950C)

Reactor

Radiation Loss = 2Btu/lb of fresh feed

Spent Catalyst = mCp x T

Heat in Step I Heat content of Feed Temp 0F Feed Slurry Recycle HCO Recycle 6710F 6720F 604.70F = = Reactor temp Density (S.G) 921.20F 921.20F 921.20F 6.08 MT/hr 4.53 MT/hr = = = 770 Kg/ hr 130.88 Kg/ hr 4693.16 Kg/ hr 258.02 Kg/ hr 552.56 Kg/ hr 1.81 Ton/ hr 280 Kg / hr 8494.62 kg/hr .8896 .9860 .9104 API 27 12 23

Slurry Flow Rate HCO Flow Rate Steam

Emergency riser steam Wye steam Fresh feed injection steam nozzle

HCO recycle dispersion steam = Slurry recycle dispersion steam = Reactor stripper steam Pre-stripping steam Total Steam = = =

Heat In the Reactor (1) Regenerator catalyst Heat Content =0.247 x 2034391.5 x (1238 - 77) = 583.396 MBTU/hr (2) Coke adsorption = Same as desorption = 18.763 MBTU/hr (3) Recyle Liquid Phase HCO = 9986.8 lb / hr x 312.21 BTU/lb

=3.12 MBTU/hr (4) Slurry = 13293.65 x lb/hr x 348.43 BTU/lb = 4.67 MBTU/hr (5) Dilant Heat Content of Steam = 18727.12 lb / hr x .485 BTU/lb0F x (482 32) 0F = 4.0872 MBTU / hr (6) Heat content of Feed (Liquid phase) = 374.03 BTU / lb x 372795.41 lb/hr = 139.44 MBTU/hr Total Heat In = 139.44+583.396+4.67+3.12+18.763+4.0872 = 753.48 MBTU/hr

Heat out From Reactor (1) Reactor Vapor = Feed Rate x Vapor phase Enthalpy of feed = 372795.4145 (lb / hr) x 650.68 BTU/hr = 242.57 MBTU/hr (2) Slurry = Flow Rate x Vapor phase Enthalpy = 13403.88(lb / hr) x 602.06 BTU/hr Slurry = 8.07 MBTU/hr (3) HCO = 9986.77(lb / hr) x 620.6 BTU/hr = 6.19 MBTU/hr (4) Radiation loss = 2(lb / hr) of Heat F.F Rate = .745 MBTU/hr (C) Heat content of spent catalyst = 405.314 MBTU/hr (D) Steam out put

= 18727.1164 lb / hr x .485 BTU/lb0F x (921.2 32) 0F = 8.076 MBTU/hr Total Heat out from Reactor = 670.965 MBTU/hr Heat in Heat out = = = 82.51 MBTU/hr This is Heat of Reaction This is an Endothermic Reaction = Heat of Reaction 753.47-670.965 MBTU/hr = 82.51 MBTU/hr

Conclusion(FCCU) Having performed the material balance and heat balance, the conclusion involves discussion of the key finding and any recommendation to improve unit operation. The discussion focuses on factor affecting product quality and any abnormal results. Other factor such as the types of catalyst and operating parameters also greatly affect the yield structure. The CCR for the operating conditions is 922.8 MT/hr which is quite near to 1000 MT/hr (actual operating value). The catalyst to oil ratio is 5.46 and the yield of coke is 3.471%. Hence we see from mass balance calculation that coke yield wt% lies in between 3 to 4. When coke yield is minimum, we can get maximum achievement of material. From heat balance calculation we get heat of reaction i.e. 82.51 MBTU/hr. This is positive, and then we can say that the heat of reaction in FCC unit is an endothermic reaction.

Safety in plant:It is important to learn about safety factor concerning the operation and maintenance of the plant, as it to learn the operation principles and

equipment function. During Normal plant operation there is usually less risk of exposure to hazards operation and unsafe condition than during a shut down or abnormal situation when maintence may be required or unexpected conditions may prevail. Exposure to hazards equipment, chemical and condition can not be complete avoided in a FCCU plant, but there should be no required activities, which can not be performed safely when the correct equipment and procedure are utilized and common sense employed. Safety Provision:Safety showers and eye wash station have been provided at appropriate location to allow washing of Hazards material from personal in case of accident contact. All employs should know the exact location of the safety showers and how to operate them. It is also important that these are mainted in good working conditions. Safety guards have been specified for equipment with moving part to protect against accident these guards must always be in place when the machine is in operation or subject to being started safety lanyards or pull cords have been provided along side all conveyance there are inter rock to drive motor so the equipment can be quickly stopped in case or emergency.

MEROX UNIT
Mercaptans are undesirable in the final products because it effects their stability, sulfur content, odour etc. Objective of merox treatment process is the conversion of Mercaptans to di-sulphides. Feed used is ATF, Gasoline, VB Naphtha and LPG. Reaction observed in the process is: 2RSH + 1/2O2 RSSR + H2O Straight-run LPG, gasoline and kerosene fractions obtained from atmospheric distillation may contain hydrogen sulphide and

mercaptans. the extent of which mainly depends upon the type of crude processed. Similar products from secondary processes such as FCC also contain hydrogen sulphide and mercaptans to a greater degree compared to straight-run products. Hydrogen sulphide is corrosive and should be remove in order to meet specifications on corrosion rate. The specification for LPG, gasolene, Kerosene and ATF include copper strip corrosion test which is a measure of rate of corrosion on copper containing materials.Mercaptans are substances with obnoxious odour and, therefore, in order to handle and store them, mercaptan level will have to be brought down to a acceptable odour level. Hydrogensulphide can be easily removed by washing with dilute caustic solution. However, for reducing the mercaptans level many processes are available like: Strong alkali-wash Copper sweetening Doctor sweetening Merox process

The removal of mercaptans may be either partial or full. The chemical treatment is based on the ability of Merox catalysts to promote the oxidation of mercaptan to disulphide using air as the source of oxygen. The overall reaction is as follows: 2RSH + 1/2O2 RSSR + H2O The oxidation is carried out in the presence of an aqueous alkaline solution such as either sodium hydroxide or potassium hydroxide. The reaction proceeds at an economical rate at normal rundown temperature of refinery streams. Low molecular weight mercaptans are soluble in caustic solution and therefore when treating LPG and light gasoline

fractions, the process can be used to extract mercaptan to the extent, they are soluble in caustic. Extraction of mercaptan reduces the sulphur content of the treated product. PROCESS DESCRIPTION OF ATF/SKO

Pretreatment for kero/ATF consists of a coalescer and caustic prewash vessel, for removal of suspended water and hydrogen sulphide, Naphthenic acid etc. Sweetening is achieved in supported catalyst bed reactor. Two reactors in parallel have been provided. Air requirement of all Merox units is supplied from a common compressor. Also, storage tanks for receipt, dilution and storage of caustic and storage for methanol have been provided. Post treatment for kero/ATF consists of caustic settling. water wash to wash of any carry-over caustic salt drier for drying and clay filters for

improving colour stability of treated product. Clay adsorbs coloured nitrogen compounds. UNIT CAPACITY: The Merox Unit for treating kerosene & ATF streams from the Atmospheric Distillation unit has been designed to feed 1.5 million metric tons per year of kerosene while processing a 50: 50 mixture of Light Arabian: North Rumalia crudes. The Unit shall operate for 345 stream days in a year. FEED SPECIFICATIONS: The kerosene to be treated in the Merox Unit shall have substantially the following properties: (i) (ii) (iii) (iv) (v) (vi) (vii) Boiling Range IBP/FBP oC Specific gravity at 15.6C Total acidity, Mg KoH/Gm Mercaptan Sulphur wt ppm Total Sulphur wt.%. H2S wt ppm Colour, Saybolt + 30 140-270 Max. 0.795 to 0.82 0.02 150 0.22 10 max

PRODUCT SPECIFICATIONS:

The Product kerosene/ATF after Merox treatment shall meet the following specifications: (i) Appearance Visually, clear, bright and

free from solid matter and undissolved water at normal ambient temperature. (ii) (iii) (iv) (v) (vi) Corrosion copper strip Corrosion silver strip Mercaptan sulphur wt ppm Doctor test Colour loss, saybolt No 1 Maximum No 0 Maximum 10-20 ppm (max.) Negative 5 Maximum when feed

stock is 25 min., provided that the feed stock comes directly from the fractionation facility. (vii) (a) in mm Hg. (b) (viii) (ix) (a) (b) Tube Rating visual Water separameter index Acidity, mg. KOH/Gm Water Separometer WATER REACTION Less than code 3 90 minimum 0.012 maximum 90 minimum Thermal stability: Filter pressure drop 25.0 maximum

index (modified)

Interface Rating Volume Change (x)

1.0 maximum 1.0 maximum 50-450 psm

Conductivity (ATF)

"H2S free fresh stock charge" shall mean fresh stock charge containing no H2S or if the fresh stock charge contains H2S, it shall be scrubbed out with caustic soda solution or sodium carbonate solution in the laboratory without exposure to oxygen. TYPE OF CATALYST USED: Catalyst used for sweetening kerosene/ATF Stream in this treating unit is merox catalyst FB which is supplied by the Universal Oil-Products Company. This catalyst is used in the two sweetening Reactors 021 R1 A and B. The catalyst is impregnated on activated charcoal beds in the reactors. Quantity of catalyst required for one impregnation in the reactors is 250 Kg. of active ingredient. The catalyst is supplied in liquid from each US gallon containing 1 kg. of active ingredient.

CONCLUSION
The report includes process description of old unit (AVU, FCCU, VBU, MEROX treatment). A detailed analysis of the FCC unit is enclosed which includes finding the catalyst circulation rate, catalyst to oil ratio used, coke yield, heat of reaction and yield of all the products obtained in FCCU. These operational parameters were found by applying mass balance and heat balance across the reactor-regenerator section.