1. BYCO PETROLEUM PAKISTAN
ORC COMPLEX II
INTERNSHIP
REPORT
[Type the document subtitle]
NAME: Muhammad ObaidullahHashmi
INSTITUTE: NED Universityofscience and technology
SUBMITTED TO: SheikhAbu Bakar
DATED: 18th
June 2015

2. Acknowledgment
Firstof all we are bow before ALLAH, The Almighty tothankforhiscountless blessingandbounties.
Secondly Iam highly thankful toEngr.Sheikh AbuBakar,ourinternship advisor, whoguidedme,
encouraged me andaccepted nothinglessthanmybestefforts. Iam alsothankful tomy friends for
theircontinuous supportandtechnical assistance. Atlastbutneverthe leastIam thankful toall
members of ORC-2(BYCO) specially Eng.AbdulWasay&Eng.Atharfortheirprecious time andvalue
-able advices.

3. BYCO IN BRIEF
Byco isPakistan’semergingcompaniesengagedinthe businessesof oil refining,petroleum
marketing,chemical manufacturingandpetroleumlogistics.HeadquarteredinKarachi,theyare
servingtheirmissiontofulfil the energydemand withinandbeyond borders.
CompaniesunderBycoumbrellaare:
 Byco Oil PakistanLimited(BOPL) Oil Refining&Chemical Manufacturing
 Byco PetroleumPakistanLimited(BPPL) Oil Refining&PetroleumMarketing
 Byco Terminal PakistanLimited(BTPL) PetroleumInfrastructure &Logistics
(FormerlyUniversal Terminal Limited)
Theyare engagedinmanufacturingof wide range petroleumproductswiththe objective toachieve
sustainable productivity,profitabilityandhighstandardstoaddressthe environment,healthand
safetyrequirements.
Byco’s operational refinery has a capacity to refine 35,000 barrels per day of crude oil into
various saleable components including Liquefied Petroleum Gas, Light Naphtha, Heavy
naphtha, High octane blending component, Motor gasoline, Kerosene, Jet naphtha, High
speed diesel and Furnace oil. They have expanded their refinery complex by setting up
another refinery with the capacity of 120,000 barrels per day which is completed.
They take pride inhavingthe largestcapacitycrude oil storage tanksinthe country.Their
petroleumdistributionnetworksupportsmovementof petroleumproductsandprovides
greatereconomiesof scales
STARTING OF INTERENSHIP
Our internshipwassetatORC IIfrom 18th
May 2015 till 19th
June 2015. Our advisor,Sheikh
AbuBakar, dividedusina groupof sevenstudents andgave usseveral tasksandassignments
so that we can enhance ourtechnical skillswithrespecttopractical approach.
UnfortunatelyPPE’s(personnel protectiveequipments)were notissuedintime andwe visit
the plantsite on 28th
May 2015 forthe firsttime but we learntoomuch inthese 16 daysof
internship.Followingisthe descriptionof plantprocesseslearntandassignmentsdone during
the internship.
PROCESS DESCRIPTION
PLANT1
The crude oil comesinplant1 whichiscrude distillationunit,here crude ispreheatedbypreheated
trainand thenby a balance draftfurnace,havingtwentyfourburners(12+12), thenenteredfrom
fourthplate of the distillationcolumn.Distillationcolumnisthe heartof thisplant.Itcontains37
plates,three strippingsectionsandnoreboiler.The reasonof omittingreboileristhatfeediscoming
at veryhightemperaturesandfurtherheating,toincrease the separationefficiency,canbe very
expensive because steamisnoteasilyavailable at600F-700F. Therefore itisbettertodecrease
partial pressuresrathertoincrease temperatures.

4. It isdone by injectingsteaminstrippingsection.The purpose if steamistodecrease the partial
pressure of lightercomponentsbelowtheirvapourpressurewhichcause decreaseinboilingpoint
and ultimatelygreatseparationefficiency.
Our crude oil alsopassesthrougha desalterbefore enteringindistillationcolumn. Desalting isthe
firstseparationprocess thattakesplace at the frontendof a petroleumrefinery.Its
primaryobjective istopreventcorrosionandfoulingof downstreamlinesandequipmentby
reducingthe oil’ssaltcontentsignificantly.Desaltingisnormallyconsideredapart of the crude
distillationunitsince heatfromsome of the streamsinthe atmosphericdistillationisusedtoheat
the crude inthe desaltingprocess.The mostcommonsaltsincrude oil are sodium, calciumand
magnesiumchlorides(NaCl ∼ 70 to80 wt%,CaCl2∼ 10 wt%,and MgCl2 ∼ 10 to 20 wt%),whichare
inthe formof crystalsor ionizedinthe waterpresentinthe crude.If saltisnot removed,the high
temperaturespresentduringcrude oil refiningcouldcause waterhydrolysis,whichinturnallowsthe
formationof hydrochloricacid(HCl),provokingseriouscorrosionproblemsinthe equipment.Partof
the salt thathas not beenremovedcanalsocause foulingproblemsinpipes,heattransfer
equipment,andfurnaces.Deactivationof catalystsmaybe enhancedbythe metals insalts,
particularlysodium.Typically,the maximumsaltcontentallowedinthe feedtocrude distillation
unitsis50 PTB (pounds of saltper thousandbarrelsof crude oil).
Desaltingconsistsof washingthe crude oil withwaterandcaustic(NaOH)
so that the saltscan be dilutedinwaterandwashedfromthe organicphase.
Fuel oil isthe bottomresidue of distillationcolumn,HGOand LGO are the bottomand middle
productsof strippers.Keroisthe topproductof strippingsectionandnaphthaisthe topproduct of
distillationcolumn.Some pumparoundsare alsousedtomaintainthe temperature of column.
All the productsof distillationcolumnexceptnaphthaare storedaftercoolingthroughpreheattrain
of inlet.Naphthawascooledfirstbypreheat trainandthenbyair coolersthensendtoplant 6 which
isNHTU (naphthahydrotreatingunit)
PLANT6
Catalytichydrotreating(HDT) isappliedextensivelyinthe petroleumrefining industrytoremove
impurities,suchasheteroatoms(sulfur,nitrogen,oxygen), PNAs(polynucleararomatics),and
metal - containingcompounds(primarilyV andNi).The concentrationof these impuritiesincreases
as the boilingpointof the petroleumfractionincreases.S - , N - , O - , and PNA – containing
compoundsare foundinlow - molecular- weightfeedstocks suchasstraight– run distillates
(naphtha,kerosene,gasoil),while high - molecular- weightfeedstocks (vacuumgasoils,
atmosphericandvacuumresidua) containthe same impurities inhigherconcentrations,aswell as
complex V - and Ni - containingcompoundsandasphaltenes. Dependingonthe nature of the feed
and the amountand type of the differentheteroatoms(i.e.,differentreactivitiescompounds),
specifichydrotreatingprocesseshave beendeveloped.The reactions occurringduringhydrotreating
are hydrodesulfurization(HDS),hydrodenitrogenation(HDN),
hydrodeoxygenation(HDO),hydrodearomatization(HDA),hydrodemetallization(HDM),and
hydrodeasphaltenization(HDAs).
The feed, whichisstraightrunnaphtha,mix withhydrogengaswhichis the top outletof plant7. A
positive displacementpumpisusedhere forhydrogenstreambecause initialpressureof hydrogen

5. gas islowerthanthe pressure of naphthastream.Thenafterpreheatingitentersthe hydrotreating
reactor where almostall the sulphurisconvertedintosulphidesof hydrogen.The bottomoutletof
reactor iswaterwashedandair cooledandpassesthroughthree phase separatorwhere H2Sand
lightgassesare separatedwhichare recycledbackto hydrogenline toreduce loadonPD pump.
Thenstreampassesthroughproductflashdrum fromwhere bottomgoestoplant8 whichisgas
plant.
PLANT8
Gas plantcomprisesof three maincolumnsi.e.de-ethanizer,de-butanizerandde-isohexanizer.
Feedtogas plantentersde-ethanizerwhichcontains29 platesandreducingdiametertoenhance
separationandto maintainvapourload.The feedentersat25th
plate and methane,ethane and
hydrogenare carriedaway withtopstream.There is no condenseratthe top of column,the reason
isobvious,one cannotcondense ethane gaswithoutusingachillersoreflux operationisdone with
the cooledbottomproductof de-butanizer.Restof the naphthaisdrawnfromthe bottomof this
columnand carriedto de-butanizer.The de-butanizeroperationisatypical separationprocessin
whichpropane andbutane i.e. LPG (liquefiedpetroleumgas) isdrawnfromthe topand rest of the
naphthafrombottom.The topproduct iscooledandfrom decanter,lightgasesventtobe fuel gas
while LPGgoesto amine absorptionchamberwhere H2Sgasis removedbyabsorptiononamine
bed,thisiscalledsweeteningof LPG.The bottomproductof de-butanizergoestode-hexanizer
whichcontains 70 plates.Here the de-hexanizerisalsocalledthe splitterwhichseparate naphtha
intoheavyandlightnaphtha.Lightnaphthagoesto plant16 (isomunit) andheavynaphthagoesto
plant7(plate former).
PLANT7
Reformingisthe processinwhichoctane numberof hydrotreatedfeedisincreasedto87-95 from
60. The plantconsistsof three catalyticreactors followedbyfurnaces.The catalystusedhere is
platinumbasedsupportedbyaluminiumbedwithsome chlorine actingasanactive sites.The main
reactionsare isomerization,dehydrogenation,dehydro-cyclyzation,hydrocrackingand
hydrogenation.
Feedfirstpassthrougha train of pre-heatexchangersthenthroughfurnace becausemostof the
reactionsare endothermic,the pressureisalsomaintainedveryhighbecauseitincrease the lifeof
catalystby preventingcokingbutitalsoenhance hydrocrackingwhichisundesirablesohydrogen
flowrate isa trade-off betweenhydrocrackingandlifeof catalyst. Afterpassingthroughall three
reactors,the product iscooledfirstbyexchangingheatwithreactantthenbypassingthroughFinn
fan cooler.Itthenentersthe flashcolumnwhere lightgasesare removedfromtophavingseventy
five percenthydrogeninit.The bottomproduct goesto distillationcolumnwhichseparate
reformate of highoctane frombottomand lightgasseshavingRVP18psi from top.
PLANT16
The isomerizationplantof Bycoisthe firstcomplete isomerizationplantof Pakistan.Thisplant
consistsof two units,Molex andPenix.Inotherindustries,whereisomerizationunitisinstalled,only
have Penix unit,Molex unitisonlyinthisByco’splant.

6. Lightersfromde-isohexanizercontainC5-C5some benzene andabout1% C7. These lightersare the
feedof Penix unitof isomerizationplant.Itpassesthroughfilterstoabsorbwaterandchlorides
because waterispermanent poisonandcanleechoutacid sitesof catalystalso itshall occupy a
large volume if vaporize incolumns(whichisundesirable).
Afterfiltersitpassesthrough colleserwhich remove smalldropletsof waterbymergingtheminto
bigparticle thenseparate thembyusingfiltersthenthe streamgoestosulphurguardbed.Sulphur
guard bedconsists of nickel adsorbentdue towhichchemisorption occur.The streamis preheated
before enteringthisadsorberandcooledafterpassingthroughitwithpreheattrainandaircoolers
to increase itsdue pointthenitpassesthroughdriershavingzeolite andaluminasupporting,this
shall make the feedalmostfree of moistures,itoperatesinleadandlegcondition,whenone bed
become saturatedthenitshall sentforregenerationandsecondbedbe onlead.
The sulphurand moisture contentof lightnaphthaisnow verylow andinthe permissiblelimitsof
feedof reactor. There are twoisomerizationreactorsfollowedbyheatexchangersbecausea
temperature of about450F isneededforreaction.The reactorshave platinumbasedcatalystwith
aluminiumbedandchlorine isactingasacidsite.
In isomerizationreactionsaformationof carboniumionisan importantstepwhichoccurdue to acid
site therefore tomaintainthesesitesperchloroethane (PERK) ismixedwithfeeditaparticular
amount.Thenthisproduct goestostabilizerbywhichwe cancontrol the RVP of thisproduct by
separatinghighvolatilegasseswhich goestoscrubberwhichisusedforneutralizingacidsby
showering causticsodafrommidand waterto dissolve salts(formeddue toneutralization).The
productstream isnowrich inisomersof pentane andhexane andbecome the feedof MOLEXunit
In MOLEX unit,physical separationisoccurringandnoreactionistakingplace.A adsorptionbedis
usedwitheightsectionstoadsorbn-paraffinandtoseparate iso-paraffin,the systemiscontinuously
regeneratingby LPGwithsmall amountof iso-butanesandpropanesinit.The flow of adsorption
chamberis controlledbyarotary valve havingtwoinletsandtwooutlets.The raffinatecontains
isomersof C5 & C6 havingRON up to 85.
EQUIPMENT OBSERVED
3-pase separator
It separatesoil,gasandwater fromeachother.Whenthe streamentersthe separator,the diverter
tube redirectthe flowprovidinginterference thatallowsliquidtosettle more readilywithinthe
separator.Free gasin the separatorflowsthrougha mistextractorthat removesanyentrained
liquidsremaininginthe gas.Gas continuestopercolate outof liquidswhilesittinginthe separator.
The gas thenflowsoutof the top of the vessel andthroughthe gas outlet.A metal protectorplate
blocksanysplashingliquidfromenteringandrisingthroughthe gasoutlet. Liquidcontinue tosettle,
withthe oil separatingfromthe waterand risingoutof solution.A weirplate allowsthe oil topour

7. intothe oil chamberwhile keepingthe waterinitschamber.The level control valves on both the oil
and water outlets allow the operator to control and measure the quality of fluid removed.
DIAPHRAGM PUMP
A diaphragmpump (alsoknownasa Membrane pump,AirOperatedDouble Diaphragm
Pump(AODD) or PneumaticDiaphragmPump) isapositive displacementpump thatusesa
combinationof the reciprocatingactionof a rubber, thermoplasticorTeflondiaphragmandsuitable
valvesoneitherside of the diaphragm(checkvalve,butterflyvalves,flapvalves,oranyotherformof
shut-off valves) topumpa fluid.
There are three maintypesof diaphragmpumps
 Those inwhichthe diaphragmissealedwithone side inthe fluidtobe pumped,andthe other
inair or hydraulicfluid.The diaphragmisflexed,causingthe volumeof the pumpchamberto
increase anddecrease.A pairof non-returncheckvalvespreventreverse flow of the fluid
 Those employingvolumetricpositivedisplacementwhere the prime moverof the diaphragmis
electro-mechanical,workingthroughacrank or gearedmotordrive,or purelymechanical,such
as witha leverorhandle.Thismethodflexesthe diaphragmthroughsimplemechanical action,
and one side of the diaphragmisopento air.
 Those employingone ormore unsealeddiaphragmswiththe fluidtobe pumpedonbothsides.
The diaphragm(s) againare flexed,causingthe volumetochange.

8. COOLING TOWERS
Industrial coolingtowerscan be usedto remove heatfromvarioussourcessuchas machineryor
heatedprocessmaterial.The primaryuse of large,industrial coolingtowersistoremove the heat
absorbedinthe circulating coolingwatersystemsusedin petroleumrefineries.
If the planthad no coolingtowerandused once-throughcoolingwater,itwouldrequire about
100,000 cubicmetresan hour[12]
andthatamountof water wouldhave tobe continuouslyreturned
to the ocean,lake or riverfromwhichit wasobtainedandcontinuouslyre-suppliedtothe plant.
Furthermore,discharginglarge amountsof hotwatermay raise the temperature of the receiving
riveror lake to an unacceptable level forthe local ecosystem.Elevatedwatertemperaturescan
kill fishandotheraquaticorganisms(see thermalpollution),orcanalsocause an increase in
undesirableorganismssuchasinvasive speciesof Zebramusselsoralgae.A coolingtowerservesto
dissipate the heatintothe atmosphere insteadandwindandairdiffusionspreadsthe heatovera
much largerarea thanhot watercan distribute heatina bodyof water.Some coal-firedand nuclear
powerplants locatedincoastal areasdo make use of once-throughoceanwater.Buteventhere,the
offshore discharge wateroutlet requiresverycareful designtoavoidenvironmentalproblems.
RO PLANT
Reverse osmosisisaprocessthatindustryusestocleanwater,whetherforindustrial process
applicationsortoconvertbrackishwater,to cleanup wastewaterortorecoversaltsfrom industrial
processes. Reverseosmosiswillnotremove all contaminantsfromwaterasdissolvedgasessuchas
dissolvedoxygenandcarbondioxide notbeingremoved.Butreverseosmosiscanbe veryeffective
at removingotherproductssuchas trihalomethanes(THM's),some pesticides,solventsandother
volatile organiccompounds(VOC's).

9. In the reverse osmosisprocesscellophane-like membranesseparate purifiedwaterfrom
contaminatedwater.ROiswhena pressure isapplied tothe concentratedside of the membrane
forcingpurifiedwaterintothe dilute side,the rejectedimpuritiesfromthe concentratedside being
washedawayinthe rejectwater. RO can alsoact as an ultra-filterremovingparticlessuchassome
micro-organismsthatmaybe too large to passthroughthe poresof the membrane.
ROTARY VALVE
A rotary valve isa type of valve inwhichthe rotationof a passage or passagesina transverse plug
regulatesthe flowof liquidorgas throughthe attachedpipes. In industry, a rotary valve (which can
also be called airlock) is often used to enter or extract material from two chambers with different
pressure level.

10. BOILER
Steamboilerorsimplyaboilerisbasicallyaclosedvessel into
whichwaterisheateduntil the waterisconvertedintosteam
at requiredpressure.Thisismostbasic definitionof boiler.The
basicworkingprinciple of boiler isveryverysimpleandeasyto
understand.The boilerisessentiallyaclosedvesselinside
whichwaterisstored.Fuel (generallycoal) isbuntina furnace
and hotgassesare produced.These hotgassescome incontact
withwatervessel where the heatof these hotgasestransferto
the waterand consequentlysteamisproducedinthe boiler.
Thenthissteamis pipedtothe turbine of thermal powerplant.
There are manydifferenttypesof boiler utilizedfordifferent
purposeslike runningaproductionunit,sanitizingsome area,
sterilizingequipment,towarmupthe surroundingsetc.
DESALTER
Crude oil passesthroughthe coldpreheattrainand isthenpumpedtothe Desaltersbycrude charge
pumps.The recycledwaterfromthe Desaltersisinjectedinthe crude oil containingsedimentsand
producedsaltywater.Thisfluidentersinthe staticmixerwhichisacrude/waterdisperser,
maximizingthe interfacial surface areaforoptimal contactbetweenbothliquids.
The wash watershall be injectedasnearas possible emulsifyingdevice toavoidafirstseparation
withcrude oil.Wash watercan come from varioussourcesincludingrelativelyhighsaltseawater,
strippingwater,etc.The staticmixersare installedupstreamthe emulsifyingdevicestoimprovethe
contact betweenthe saltinthe crude oil andthe wash waterinjectedinthe line.
The oil/watermixture ishomogenouslyemulsifiedinthe emulsifyingdevice.The emulsifyingdevice
(as a valve) isusedtoemulsifythe dilutionwaterinjectedupstreaminthe oil.The emulsificationis
importantforcontact betweenthe saltyproductionwatercontainedinthe oil andthe washwater.
Thenthe emulsionentersthe Desalterswhere itseparatesintotwophasesbyelectrostatic
coalescence.
The electrostaticcoalescenceisinducedbythe polarization effectresultingfromanexternal electric
source.Polarizationof waterdropletspullsthemoutfrom oil-wateremulsionphase.Saltbeing
dissolvedinthese
waterdroplets,isalso
separatedalongthe
way.

11. ASSIGNMENTS AND TASKS
 To calculate polytropicandvolumetricefficiencyof centrifugal compressorwithdata
sheetgiven.
 To calculate latentheatof highpressure steamwhile usinginheatexchangertoheat
H2+HC withCp. of liquidandvapourphase given.
 To studytypesof flowmeters.
 Designingof orifice platesbyusingGPSA andEXON-MOBILmethod.
 Comparingthe propertiesof pure andhypocomponents inhysis.
 Studyingtypesof storage tanks.
 Reasonof colourcoatingon pipes.
 Calculatingthe efficiencyof pumpsusingpressure dropandamperes.
 Studyingthe effectof strippingsteamincrude distillationtower.
 Studyingthe typesof pumpcasing.
 Studyingthe effectof differentparametersondistillationcolumn.