سەفەرێک بۆ دەورەی سەیفی لە کومپانیای کار گرۆپ بەشی نەوت ڕیفاینەری قوتابیانی پەیمانگای ماد

1. “SUMMER TRAINING REPORT ON REFINERY PROCESSES”
FOR THE DURATION 01-8-2023 TO 15-8-2023
SUBMITTED TO ¾
KAR COMPANY
SUBMITTED BY ¾
Mad Institute
Petroleum Refinery Department
shahyad.zkri00@gmail.com
SET BY:
SHAHYAD ZKRI SHWAN WAJI ZIAD AHMAD WAYSI AZAD MUHAMAD

2. PREFACE
Vocational Training plays a vital role in the progress of future
engineers Not only does it provide insights about the company
concerned, but it also bridges the gap between theory and practical
knowledge. I was fortunate that I was provided with an opportunity
of going vocational training at Kar refinery Company in Erbil. The
experience gained during this short period was fascinating to say the
least It was a tremendous feeling to observe the undergoing projects
and know the role of a designing Company in any project In the
duration of my training I realized that in order to be a successful
Chemical Engineer one needs to possess a sound theoretical base
along with the acumen for effective practical application of theory.
Thus, I hope that this industrial training serves as a stepping stone for
me in future and help me carve a niche for myself in this field.

3. ACKNOWLEDGEMENT
The internship opportunity I had with "Kar refinery Company, Erbil" was a
great chance for learning and professional development. Therefore, I
consider myself as a very lucky individual as I was provided with an
opportunity to be a part of it. I am also grateful for having a chance to meet
so many wonderful people and professionals who led me though this
internship period.
I express my deepest thanks to Ari Sir, for taking part in useful decision &
giving necessary advices and guidance and arranged all facilities to make
my training easier choose this moment to acknowledge his contribution
gratefully.
Bearing in mind previous I am using this opportunity to express my
deepest gratitude and special thanks to Mr. wasfi the Manager of HSE Sir
and Mr. Karwan Sir and others who in spite of being busy with duties,
took time out to hear, guide and keep me on the correct path and
allowing me to carry out my project during the training.
Bearing in mind previous I am using this opportunity to express my
deepest gratitude and special thanks to Mr. wasfi the Maneger of HSE
Sir and others who in spite of being busy with duties, took time out to
hear, guide and keep me on the correct path and allowing me to carry.
out my
project during the training
I am pleased to express my heartfelt sentiments and extend my
deepest sense of gratitude to Manager of Mad institute Ms. Berivan
for her meticulous and invaluable guidance during my vocational
training.

4. ABOUT THE COMPANY
AR Company is a privately owned company, established in 1999 with its
main headquarter in Erbil and with branch offices in most Iraqi
governorates in addition to the offices abroad in Turkey, Jordan and
representative in UAE and USA. The company is commenced its work in
the field of engineering and construction projects and focused mainly on
the strategic projects in energy sector (Oil, Gas and electricity). Kar
Company has accomplished nearly 2400 projects since 2003 in major
parts of Iraq province in the rehabilitation of the roads, water supply,
sanitation, communication, constructions of schools and hospitals.
A part of above projects, Kar Company participated in the field of real
estate investment, constructed housing complex in Ashti City with total
number of 4500 residential units besides multi story apartment buildings,
in addition started the construction of Banu Mall, constructing of 13 story
building for Kar main headquarter, and constructing KAR City complex in
Duhok with total number of 1000 residential units. Kar Company executed
many projects in the field of Oil and Electricity including Khurmala Oil
Field, Erbil refinery, several electrical substations in Erbil and Duhok, Najaf
cement factory and recently constructing Khurmala Power plant with a
capacity of 1000 MW. For all projects, the total number of KAR employees
reaches 34000 including specialized engineers, designers, technicians,
procurement and construction. Kar Group is composed of a group of
affiliate KAR company each being specialized in different type of activity
including: investment, construction, transportation, procurement and
supply, insurance, security and indicated in profile underneath.

5. Petroleum Refining
Pipelines
Oil and Gas and Electricity
Water and Waste water management
Power
Infrastructure
Storages and Terminals
Petrochemicals
MISSION
Achieve 'Customer Delight' through innovative, cost effective and value
added consulting and EPC services.
To maximize creation of wealth, value and satisfaction for stakeholders
with high standards of business ethics and aligned with national
policies.
AREAS OF EXPERTISE

6. INTRODUCTION TO REFINING
WHAT IS REFINING?
Refining is an industrial process of purification of a substance or a form
whereby crude oil undergoes various chemical processes to convert it into
products such as gasoline, diesel fuel, asphalt base, heating oil, kerosene and
liquefied petroleum gas. Refineries are very complicated chemical
processing plants that use reactions and separations to convert crude oil
into gasoline and other valuable products. Major facility of a refinery
includes the receipt and storage of crude oil, dispatch facilities and storage
of products, processing units, utilities
generation facilities, effluent treatment plants and flare systems etc.
Refining is carried out in three major steps-
Separation
Conversion
Purification

7. WHY DO WE REFINE?
Crude oil is a natural occurring mixture of hydrocarbons formed from
organic matter which is a complex mixture of thousands of compounds of
hydrocarbons, traces of other compounds like sulphur, nitrogen, oxygen
and other metals. Crude oil cannot be used as it occurs in nature, other
than burning for fuel, which is wasteful. It must be refined to manufacture
finished products such as gasoline and heating oil. It can be classified on
the basis light/medium/heavy crudes, on the basis of sulphur content,
paraffinic/naphthenic/aromatic crudes, waxy/non waxy crudes, lube
bearing/ non lube bearing crudes etc.
CRUDE OIL CHARACTERISTICS
ØAPI GRAVITY:
Crude density is commonly measured by API gravity. API gravity
provides a relative measure of crude oil density.
API = (141.5 / SP. GR. @60 deg F) - 131.5
Light Crude: API>300
Medium Crude: API: 25-300
Heavy Crude: API: 20-250

8. SULPHUR CONTENT : Sulfur content measures if a crude is sweet
(low sulfur) or sour (high sulfur)
Typically less than 0.5% sulfur content - Sweet
Typically greater than 1.5% sulfur content – Sour
SALT CONTENT - expressed as NaCIpresent in lb/ 1000 barrel (ptb)
NITROGEN CONTENT - High Nitrogen is undesirable, basic nitrogen
destroys active sites of catalyst.
METAL CONTENT - Metals are typically Ni, V, Cu, Fe etc. Metal
content that
may vary from 10 PPM to 1000 PPM.
PETROLEUM PRODUCTS
PETROL
Petrol (motor gasoline) is made of cyclic compounds known as
naphtha's. It is made in two grades: Regular (91 octane) and Super
or Premium (96 octane), both for spark ignition engines. These are
later blended with other additives by the respective petrol
companies.
JET FUEL/DUAL PURPOSE KEROSENE
The bulk of the refinery produsced kerosene is high quality aviation
turbine fuel used by the jet engines of the domestic and
international airlines. Some kerosene is used for heating and
cooking.

9. DIESEL OIL
This is less volatile than gasoline and is used mainly in compression ignition
engines, in road vehicles, agricultural tractors, locomotives, small boats and
stationary engines. Some diesel oil (also known as gas oil) is used for
domestic heating
FUEL OIL
A number of grades of fuel are produced from blending. Lighter grades are
used for the larger, lower speed compression engines (marine types) and
heavier grades are for boilers and as power station fuels.
BITUMEN
This is best known as a covering on roads and airfield runways, but is also
used in industry a waterproofing materials.
SULPHUR
Sulphur is removed from the crude during processing and used in liquid form
in the manufacture of fertilizers.

10. Process
flow
diagram
of
a
typical
refinery
OVERVIEW OF REFINING OPERATIONS

11. DESALTER
Desalting process is used for the removal of salts like chlorides of calcium,
magnesium, and other impurities as these are corrosive in nature and
predominantly chloride salts can combine with water to form hydrochloric
acid in atmospheric distillation unit overhead systems causing significant
equipment damage and processing upsets. There are two types of desalting-
single and multistage desalting. Salt content in commercial crude is moreover
around 10-200pb, earlier 10-20 ppb were considered satisfactorily low, but
now a days refiners aims at 5 ppb or less which is not possible through single
stage desalting, hence multistage desalting unit is required.
Desalting process basically consists of three main stages- Heating, Mixing
and Settling.
Crude oil must be removed from crude oil prior to processing. Crude oil is
pumped from storage tanks and preheated by exchanging heat with
atmospheric distillation product streams to approximately 120°C Inorganic
salts are removed by emulsifying crude oil with water and separating them in
a desalter. Salts are dissolved in water and brine is removed using an
electrostatic field and sent to the waste water treatment unit.

12. CDU
The crude oil distillation unit (DU) or Atmospheric distillation Unit is the
first processing unit in all petroleum refineries. The CDU distills the
incoming crude oil into various fractions for further processing based on
their different boiling point ranges. Various steps in CDU are Preheating
of desalted crude, Preflashing, Distillation, and finally stabilization of
Naphtha.

13. Distillation concentrates lower boiling point material in the top of
the distillation tower and higher boiling point material in the
bottom. Heat is added to the bottom of the tower using a reboiler
that vaporizes part of the tower bottom liquid and returns it to the
tower. Heat is removed from the top of the tower through an
overhead condenser. A portion of the condensed liquid is returned to
the tower as reflux. The continuous vaporization and condensation
of material on each tray of the fractionating tower is what creates
the separation of petroleum products within the tower. The most
common products of CDU are fuel gas (butane & lighter gas),
Naphtha, kerosene (including jet fuel), diesel fuel, gas oil and
residue. They runs at a pressure slightly above atmospheric pressure
in the overhead accumulator and the temperature above
approximately 750°F (400°C) are avoided to prevent thermal
cracking of crude oil into gases and coke.
VDU
The atmospheric bottoms also called reduced crude oil, from the
atmospheric column is fractionated in the Vacuum Distillation tower.
Products that exist as a liquid at atmosphericpressure will boil at
lower temperature when pressure is significantly reduced. Absolute
operating pressure in a Vacuum tower can be reduced to 20mm of
Hg or less (atmospheric pressure is 760mm of He). In addition,
superheated steam is injected with the feed and in the tower bottom
to reduce hydrocarbon partial pressure to 10mm of Hg or less.

14. Atmospheric Residue is heated to 750°F (400°C in a fired heater and fed
to the vacuum distillation tower where it is fractionated into light gas oil,
heavy gas oil and vacuum residue.
HYDROTREATER
Hydrotreating is a catalytic process to stabilize products and remove
objectionable elements like sulfur, nitrogen and aromatics by reacting
them with hydrogen. Cobalt Molybdenum catalysts are used for
desulfurization. When nitrogen removel is required in addition to sulfur,
nickel-molybdenum catalysts are used. In some instances, aromatics
saturation is pursued during the hydrotreating process in order to
improve diesel fuel performance. Most hydrotreating reactions take place
between 600 800°F (315-425°C) and at moderately high pressure 500-
1500psi (35-100 bar). As coke deposits an the catalyst, reactor
temperature must be raised. Once the reactor temperature reaches
about 750°F (400°C) the unit scheduled for shutdown and catalyst
replacement.

15. FCCU
The FCC is considered by many as the heart of modern petroleum
refinery. FCC is the tool refiners use to correct the imbalance between
the market demand for lighter petroleum products and crude oil
distillation that produces an excess of heavy, high boiling range
products. The FCC unit converts heavy gas oil into gasoline and diesel.
The FCC process cracks the heavy gas oils by breaking the carbon bonds
in large molecules into multiple smaller molecules that boil in a much
lower temperature range. The FCC can achieve conversion of 70-90% of
heavy gas oil into products boiling in the heavy gasoline range. The
reduction in density across the FCC also has the benefit of producing a
volume gain which as a result has a significant effect on refinery
profitability.

16. FCC reactions are promoted at high temperatures from 950-1020°F (510-
550°C) but relatively low pressures of 10-30psi (1-2bar). At these
temperatures, coke formation deactivates the catalyst by blocking reaction
sites on the solid catalyst. The FCC unit utilizes a very tine powdery catalyst
known as a zeolite catalyst that is able to flow like a fluid in a fluidized bed.
Catalyst is continually circulated from the reactor to a regenerator where
coke is burned off in controlled combustion with air creating CO, CO2 , Sox
NOx as we as some other combustion products.
Feedstock gas oil is preheated and mixed with hot catalyst coming from the
regenerator at approx 1400°F. The hot catalyst vaporizes the feedstock and
heats it to the reaction temperature. To avoid overcracking, which reduces
yield at the expense of gasoline, reaction time is minimized. The primary
reaction occurs in the transfer line going to the reactor. The primary
purpose of the reactor is to separate catalyst from reaction products.
COKER (VISBREAKER)
Coking and Visbreaking are both thermal decomposition processes. With
the exception of the coking process, formation of coke in a petroleum
refinery is undesirable because coke fouls equipment and reduces catalyst
activity. However, in the coking process, coke is intentionally produced as
a byproduct of vacuum residue conversion from low value fuel and asphalt
into higher value products. The most common form of coking process is
Delayed Coking where vacuum residue is thermally cracked into smaller
molecules that boil at lower temperatures. Products include naphtha, gas
oils and coke. Coke is sold as a fuel or specialty product into steel and
aluminum industry after calcining to remove impurities. Vacuum residue is
fed to the coker fractionators to remove as much as light material as
possible.

17. Bottoms from the fractionators are heated in a direct fired furnace to
more than 900F (480C) and discharged into a coke drum where thermal
cracking is completed. High velocity and steam injection are used to
minimize the coke formation in furnace tubes. Coke deposits in the drum
and cracked products are sent to fractionator for recovery. Coke drum
typically operate in the 25-50psi (2-4bar) range while the fractionators
operates at a pressure slightly above atmospheric in the overhead
accumulator. Fractionator bottoms are recycled through the furnace to
extinction. Coker light ends are highly unsaturated and are recovered as
an olefin feed source for alkylation.
possible. Bottoms from the fractionators are heated in a direct fired
furnace to more than 900F (480C) and discharged into a coke drum
where thermal cracking is completed. High velocity and steam
injection are used to minimize the coke formation in furnace tubes.
Cokedeposits in the drum and cracked products are sent to f
ractionator for recovery. Coke drum typically operate in the 25-50psi
(2-4bar) range while the fractionators operates at a pressure slightly
above atmospheric in the overhead accumulator. Fractionator
bottoms are recycled through the furnace to extinction. Coker light
ends are highly unsaturated and are recoveredas an olefin feed
source for alkyl ation.