1. INTERNSHIP REPORT
H.M.SHOAIB (D-14-CH-37)
Internship
At
Byco Oil Refinary Pakistan Limited.
Dawood University Of Engineering & Technology Karachi
Chemical Department

2. INTERNSHIP REPORT
SUBMITTED TO
SHAHID YOUSUF
(ADVISORY)
SUMITTED BY
H.M.SHOAIB
Roll # D-14-CH-37
B.E Chemical Engineering
Session (2014-2018)
DEPARTMENT OF CHEMICAL ENGINEERING

3. ACKNOWLEDGMENT
Success and achievement is possible only through hard work, determination and
strong will. I am grateful to ALMIGHTY ALLAH who gave me the strength to
think, plan and act accordingly which makeme possible to completemy
internship.
Though it is a literary tradition to acknowledgethecontribution and help by
different people& organization in thecompletion of an internship, but as a
matter of fact some wordscannot express our gratitudeto thevarioushelping
hands. It is very difficult to appreciateeach and every person for his
contribution, but thereis a standing contribution of my following advisors, who
were there with me at thetime I needed them & without thereguidelineit
would be difficult for meto completethisinternship successfully.
NAME DESIGNATION
 MUSHTAQ AHMAD
KHOKHAR
 FASIAL BAIG
 SHAHID YOUSUF
 QAZI BILAL
 MANAGER ADVISORY
OIL
REFINING BUSINESS
 MANAGER BLACK
OILUtilities
 ADVISORY
 ADVISORY

4. HSEQDEPARTMENT
HSEQ stands for Health, Safety and Environment. As technology develops, the industries
become more complex and dangerous. To tackle any emergencies that might arise in any
industry there is a need of means of ensuring safety and health. Thus the concept of a HS
department which was responsible to maintain health and safety came into being. With time it
was observed that industries contribute a lot to the pollution of the environment. Hence the
authority to monitor the environment and ensure product quality, the alphabet E which stands
for environment was integrated with HS to make the HSE department. The quality of the
product has to be monitored to thus another department which ensures quality is integrated
into the HSE, this makes the HSEQ department
BYCO has a fully functional HSE department that runs around the clock 365 days an year. The
details of which are highlighted below.
The HSE department of BYCO can be broken down into:
• ERT (Emergency Response Team)
• Medical Services
• Process Safety
• Construction Safety and Analysis
• IMS (Integrated Management Safety)
Safety
The processes taking place in a refinery are very sensitive and extremely hazardous. The HSE
department takes step to ensure safety and incase of any emergency has the capability to
respond to it.
Individual Safety:
In BYCO, the HSE department their safety moto is “Safety starts from you”. Every individual that
enters the refinery is entrusted with the responsibility to ensure his safety and the safety of the
equipment.
There is a strict code on clothing inside the refinery, no one can enter without wearing a
helmet, safety shoes and an overall. Other than that for further safety PPEs (Personal Protective
Equipment) like googles, sound mufflers, gloves, SCBA (Self Containing Breathing Apparatus) etc
are readily available in case of need.
Other than that the HSE also arranges seminars and trainings to spread safety skills and habits
in the individuals working in the refinery.

5. Equipment Safety:
As much as human safety is important, the safety of equipment is essential too. HSE
department regularly inspects equipment to check if it is in proper working condition and
establishes rules to operate or work with the equipment.
In case of maintenance of equipment there is a proper work permit system. These work permits
are only provided after proper classification of the type of work, hazard analysis and insurance
that the work will not affect the other equipment. There are four types of work permits at
BYCO:
 Hot Permit: Hot work is any process that can be a source of ignition when flammable
material is present or can be a fire hazard regardless of the presence of flammable
material in the workplace. For such work a hot work permit is required.
 ColdPermit: A cold work permit shall be obtained for all general work that does not
involve activities related to hot work, i.e. the tolls and equipment used or the work
itself do not generate any spark. And cold work refers to general maintenance work on
the plant or equipment where the uses of any open flames, any source of ignition or
any electrical equipment is not allowed.
 Confined Space Certificate: A confined space is an enclosed area with limited
space and accessibility. To work in such places proper measures and equipment is
required. After the arrangements are made the HSE analyzes the work places and
approves the certificate to allow the progression of the work.
 ExcavationCertificate: A refinery is a series of complex pipes and equipment
which are at times even installed underground. Thus before any excavation work a
proper certificate is required to ensure that due to the relevant work none of the
underground installations are effected.
 Emergency Response Team:
HSE has developed an Emergency Response team to tackle any emergency that might arise in
the refinery. The ERT is properly trained in search and rescue as well as tackling emergencies
like fire etc.
The ERT team has two ambulances and two fire trucks which are on the standby around the
clock and have the ability to reach the site of any emergency within a minute and a half.
The usual emergency in any refinery is the threat of fire. The first line of defense against these
is fire alarms and water sprinklers installed in potential places where a fire can occur. The ERT
has two state of art fire trucks which have ability to tackle fire with the means of water, foam
and DCP (Dry Chemical Powder). There are also fire extinguishers with DCP, CO2 and foam
installed around the plant.

6.  Emergency Informationand EvacuationPlan:
The first step to tackle an emergency is its information. The HSE has a hotline established where
any emergency can be informed at any time. Other than that MCPs (Manual Call Points) are
installed at different points across the refinery, which when activated send an indication to the
ERT informing them of the location of the emergency.
There are 6 assembly points in the plants, these points are established for cases of emergency
in which the workers have to be evacuated and these serve as muster points. The ERT also
analyzes and designs evacuation plans which are installed at all major facilities in the plant
indicating the path to the nearest Assembly Point.
Health
HSE has a functional clinic and hospital at the plant. This clinic is manned by doctors and nurses
all around the year. All basic first aid services are present at the clinic. The clinic has all modern
equipment like ECG, defibulators and x ray machines etc. It also has an operation theater where
minor operations can take place. In case of severe emergencies the clinic has 2 operational
ambulances on standby to take the victims to the nearest biggest hospitals.
The Health department also provide first aid trainings. It also holds seminars to impart healthy
habits and information to safeguard against different diseases.
Environment and Quality Management
Another essential component of HSE is Environment and Quality Management. It is a social
responsibility of engineers and operators to protect the environment, this is monitored by the
HSE department.
HSE department has a laboratory where the product and different refuse of the plant. The
products are analyzed periodically to analyze quality of the product. Similarly the refuses and
discharges are analyzed. If in case they excide the set limit, the HSE analyzes the process to find
the root cause of the deviation and eliminate.

7. The main component of Quality Management is the IMS and ISO certification. IMS is integrated
management systems this system composes of internal and external auditors of the HSEQ
department that periodically analyze the plant to ensure quality, health, safety and
environmental protection
Lab
The lab is the hearth of the quality and environment management department. The lab
preforms test on the different products, feed and discharges of the process to look for
anomalies. In case of detection of anomalies processes are analyzed to find the root cause and
then steps taken to remove them.
The Lab has the following testing facilities:
• Gas Testing
• Environment Testing
• Waste Water Testing
• Fuel Testing
• Utility Water Testing
• Crude Testing
Different equipment present in the lab include:
 Gas Chromatography: The chromatography used in analytical chemistry for
separating and analyzing compounds that can be vaporized without decomposition.
 Gas Liquid Chromatography: An analysis technique for finding the constituents
of a liquid mixture.
 Viscosity Bath: Apparatus used to find viscosities of different crude components.
 Flash Point: Analysis of flammability of fuels.
 Oxidation Stability: An index of the rate of oxidation which dependent on the
quality and type of base oil as well as the additive package used.
 Distillation: Test for crude components
 Spectrophotometer: Used to detect and quantify Mercaptans (Sulphur containing
hydrocarbons) in a sample.
 Spectrode:Used for metal analysis of sample.
Similarly the following tests are conducted in water analysis:
 Analysis of impurities:like Zinc, Phosphate, Chlorides, Free Chlorine, Iron and
Sulphides.
 Laglier Index: It simply indicates the driving force for scale formation and growth in
terms of pH.
 Ryznar Stability: The Ryznar stability index is calculated to give an indication about
the potential of scale and indirectly the corrosion potential.

8. SPM(Single Point Mooring)
The Single Point Mooring (SPM) facility being set up for the first time in Pakistan will
revolutionize the handling of petroleum and oil products in the Country. The facility is being
setup to allow the handling of imported crude oil and other petroleum products through the
SPM – an open sea anchorage with sub-sea and sub soil pipelines connecting it to the on-shore
facilities.
This facility is being set up in the deep sea, at a distance of approximately of 15 km from the
Byco site located at Mouza Kund, Balochistan, Pakistan. The floating jetty will be connected to
crude oil tank farm of approximately 130,000 metric tons, via 3.3 km on-shore pipelines and
11.5 km off-shore 28" pipelines.
The SPM can currently handle vessels of 100,000 deadweight tonnage (“DWT”), and has the
expansion capacity to add two more pipelines which shall enhance facility's throughput. It also
has the Phase 2 capacity to handle Very Large Crude Carriers (“VLCC”s) of up to 250,000 DWT.
BOOSTER PUMP
A booster pump is a machine which will increase the pressure of a fluid, generally a liquid. It is
similar to gas compressor. Crude oil comes from decanting area to operation plant through
booster pump.
CDU( CRUDE DISTILLATION COLUMN)
DISCHARGE PUMP
A centrifugal pump converts input power to kinetic energy by accelerating liquid in a revolving
device – an impeller. Discharge pump send the crude oil to the heat exchanger.
Heat Exchanger
A heat exchanger is a device used to transfer heat from one medium to another. When crude
enter in the heat exchanger increase the temperature (120 to 150 0
C). Heating medium used in
the heat exchanger is product oil and then crude oil sent to the desalter.
TYPES OF HEATEXCHANGER
 Hair pinheatexchanger
 FinFan heatexchanger
 Trim Coolerheatexchanger
 Inside Shell &Tube heatexchanger

9. DE-SALTER
A desalter is a process unit in an oil refinery that removes salt from the crude oil. The salt is
dissolved in the water in the crude oil, not in the crude oil itself. The desalting is usually the first
process in crude oil refining. The salt content after the desalter is usually measured in PTB -
pounds of salt per thousand barrels of crude oil.
Another specification is Basic sediment and
water.
The term desalter may also refer to a water desalination facility used to treat brackish water
from agricultural runoff. This may be done either to produce potable water for human or
animal consumption, or to reduce the salinity of river water prior to its crossing an international
border, usually to comply with the terms of a treaty. Desalters are also used to treat
groundwater reservoirs in areas impacted by cattle feedlots and dairies.
The salts that are most frequently present in crude oil are calcium, sodium and magnesium
chlorides. If these compounds are not removed from the oil several problems arise in the
refining process. The high temperatures that occur downstream in the process could cause
water hydrolysis, which in turn allows the formation of corrosive hydrochloric acid. Sand, silts
and salt cause deposits and foul heat exchangers or result in plugging. The need to supply heat
to vaporize water reduces crude pre-heat capacity. Sodium, arsenic and other metals can
poison catalysts. By removing the suspended solids, they are not carried into the burner and
eventually flue gas, where they would cause problems with environmental compliance such as
flue gas opacity norms.
When crude oil enter in the de-salter we mixed water and chemical (de –mulsifer) to
separate salts and some amount of water in the crude oil.Again pre-heating to increase
temperature(170-180 0
C).

10. PRE-FLASH COLUMN
The crude processing capacity of these units, we want to incorporate the pre-flash
column(PFC).The purpose of this column is to reduce the load of CDU overhead section.This will
be done by flashing the crude of (180-200 0
C) at nearly atm pressure and the flash vapour will
be stripped off to produce the 10% un-stabilize Naptha. Chemical are used in pre-flash column
are given below:
 Caustic acid are used for trays forming, stop corrosion
 Phylum plus are used for internal coating
The remaining crude send to heat exchanger to increase the temperature (200-250 0
C).
FURNANCE
Furnance is a device used for high temperature heating. The name derives from greek
word fornax, which means oven.
Crude oil enters in the born furnance and this furnance raise its temperature (360 -370 0
C) by
fuel oil using as a heating medium. Furnance heated the crude oil and then send to CDU(crude
distillation unit) or Distillation Column.

11. RADIANTSECTION
The radiant section is where the tubes receive almost all its heat by radiation from the flame. In
a vertical, cylindrical furnace, the tubes are vertical. Tubes can be vertical or horizontal, placed
along the refractory wall, in the middle, etc., or arranged in cells. Studs are used to hold the
insulation together and on the wall of the furnace.
CONVECTION SECTION
The convection section is located above the radiant section where it is cooler to recover
additional heat. Heat transfer takes place by convection here, and the tubes are finned to
increase heat transfer.
DISTILLATION COLUMN
Crude Distillation Unit (CDU) as the name suggests is a distillation process in which distillation
of crude is done. Distillation is a physical separation process in which Crude oil is split into its
different components on the basis of volatility.

12. The crude oil distillation unit (CDU) is the first processing unit in virtually all petroleum
refineries. The CDU distills the incoming crude oil into various fractions of different boiling
ranges, each of which are then processed further in the other refinery processing units. Crude
Oil Distillation unit, Distills the incoming crude oil into various fractions for further processing in
other Units. Crude oil is sent to the atmospheric distillation unit after desalting and heating. The
purpose of atmospheric distillation is primary separation of various 'cuts' of hydrocarbons.
There are four products by Distillation in distillation column are given below:
 Naphtha: Both Light and Heavy Naphtha streams.
 Kerosene: A blend of different components which can be further separated into fuels
of different characteristics
 Diesel Streams:Diesels blends which are later separated into High Speed Diesel, Low
Speed Diesel etc.
 Residues: Mainly considered as Furnace Fuel Oil.
Distillation Column (CDU) PFD:

13. DistillationTower Highlights:
 Number of Trays: 38 in total.
• Type of Tray: Fixed Valve Plates.
• Refinery Capacity: 35,000 barrels per day
• Top Pump Around: Available between Plates 8 and 10
• Bottom Pump around: Available between Plates 28 to 33
• Feed Charge: At the 34th Plate
• Feed Inlet Temperature: 370 0C.
• Reboiler: No reboiler, temperature controlled by the means of direct contact with
superheated steam at 460 0C
Vacuum distillationunit
Further distills the residue oil from the bottom of the crude oil distillation unit. The vacuum
distillation is performed at a pressure well below atmospheric pressure but in ORC-1 Vacuum
Distillation is not used.
In ORC-2 Vacuum Distillation column are installed but ORC-2 are being processed.
NAPHTHASPLITTER:
Naphtha is composed of a lighter and a heavier fraction. Light
naphtha is very valuable as it is a primary component of Gasoline, a fuel for automobile .
Whereas heavy naphtha has to be reformed before it can be blend into Gasoline to improve its
(RON) Research Octane Number or in basic terms its efficiency.
Naphtha comes to the Pre-flash column and Crude Distillation column(CDU) are sent to the
naphtha splitter column. In the column due to the difference in volatility the light naphtha
stream separates from the heavy naphtha. The light naphtha is then cooled and stored in the
reflux drum. On cooling the light naphtha condenses and the even lighter components plash
out to the flare. The light naphtha is then sent to the LPG Plant and heavy naphtha is collected
from the bottom and sent to the Reformer section.
HSD(HIGH SPEEDDIESEL):
The HSD removed from the 22nd plate of the distillation tower is then treated in the HSD
treatment section. Here the HSD is split into two streams each passing through a side stripper
where unwanted impurities mostly kerosene composites are stripped out. These strippers are
used to increase the flash point of diesel by stripping out lighter components. After stripping
these streams are then rejoined and exported out of the CDU.

14. LSU(LPG SEPARATOR UNIT)
In this unit, LPG is extracted from Light Naphtha coming from the splitter. LPG is a
mixture of 60% Propane and 40% Butane but the LPG produced in BYCO is primary Propane
with traces of Butane.
The process is similar to stripping in which the Naphtha feed is heated in a tray columns in
which Ethane and Propane and finally Butane are removed in separate columns. After LPG
removal from the Light Naphtha stream, it goes into Merox unit after which both Naphtha and
LPG are stored in their respective storage tanks.
MEROX UNIT(MEROX TREATOR)
Merox is a term drive from MER which stands for Mercaptance and OX which stands for
oxidation. This process is used to remove mercaptance i.e the sulphur containing
hydrocarbons from the LPG and NAPHTHA streams. It can also be used to treat Kerosene.
Sulphur presence in fuel is highly undesirable as it makes the fuel sour. Use of such fuel in
combustion engines can lead to corrosion and production of Sulphur oxides which are primary
and secondary pollutant. In Merox treatment these sulphur compounds are converted to liquid
disulphides which can be removed through separation techniques.
Merox treatmet is done by means of caustic showering. The reaction involved in the processes
are as follow:
Step 1: 2RSH + 2 NaOH → 2NaSR + 2 H2O
Step 2: 4NaSR + O2 + 2H2O → 2RSSR + 4NaOH
Overall Reaction: 4 RSH + O2 → 2RSSR + 2H2

15. The Merox treater flow for LPG and Naphtha are the same. The Flow is shown below:
LPG & NAPHTHAMEROX
After passing the reactor the liquid streams pass through separators which remove any oil-
soluble substances, organometallic compounds (especially copper) and particulate matter.
PREWASHER
The Naphtha or LPG Stream are sent into the prewash tank. In the prewash tank there is a set
level of caustic through which the products are bubbled out and remove the mercaptance. The
density difference causes the Naphtha and LPG to move towards the top and the caustic to
settle down.
EXTRACTOR
After prewashing the Naphtha and LPG are sent through the extractor. Caustic is showered
from the top and it helps in absorbing the sulphur as shown in the step one of the reaction.
SETTLER
After extraction the Naphtha and LPG pass into the settler where due to difference in densities
the caustic settles down and the sweetened Products are received on the other end.
KEROSINE MEROX
The MerOx treater flow for Kerosene is different. This is because of very small difference in
densities with caustic, hence it can’t be separated on basis of densities.

16. PREWASHER
The kerosene stream after prewashing is fed to the Settler Reactor. Prewashing process are
discussed the above.
SETTLER REACTOR
Settler reactor is a fixed bed of Charcoal. The Kerosene is then reacted with caustic and a
catalyst. After the reaction the product stream is removed from the bottom and fed to the salt
filter.
SALT FILTER
The salt filter has a bed of salt, this salt absorbs the water which forms as a result of the
reaction.
CLAY FILTER
After passing the salt filter the kerosene enters the clay filter, in this filter all the solid particles
are removed. The caustic removed is sent for regeneration. The sweetened kerosene is
rundown as a product.
REGENERATION OFCAUSTIC
The regeneration is similar for both LPG and Kerosene MerOx. The reacted caustic is first
oxidized to form Disulphides (As shown in the second reaction) and pure caustic is formed as a
byproduct. This caustic is again used as a washing and reacting agent in the system. The
Disulphides are insoluble in the caustic and are separated in a 3 phase separators where the
impure gases flash out, the caustic is removed from the middle and the Disulphides are
removed from the bottom.
HYDROTREATER & REFORMER UNIT
Hydro treatment or hydro processing is a pretreating step before the Heavy Naphtha can be
reformed. During the hydro treatment process the following are removed from the Naphtha
stream:
 Sulphur and its compounds
 Nitrogen and its compounds
 Metallic components removed.
These removals are important because most of these compounds act as catalyst poison in the
reformer as well as it reduce load on the reformer as most of the un-saturation is already
removed.
The reaction that take place in the reactor are catalytic so Cobalt Molybdenum catalyst is used
and the reaction temperature of 300 0
C are maintained through pre heating.

17. The following reactions that take place in the reactor:
 Hydro de-sulfurization.
 Hydro de-nitrogenation.
 Hydro cracking.
 Hydro de-matallization.
 Hydro de-oxygenation.
After hydro treatment the Heavy Naphtha is ready for reforming.
The Naphtha from storage or distillation column is pre-heated to the hydro treator reactor
conditions after which the product is sent to the separator where the impure gasses like
Nitrogen, Sulphur, Oxygen and water vapours are separated as fuel gas. The hydro-treated
product is then sent to the de-sulphurizer where sulphur is extracted from the hydro-treated
product. The bottom product of the de-sulfurizer is hydro de-sulfurized stream that can be used
as reformer feed or stored as sweet naphtha.
REFORMER UNIT
The reformer unit is used to convert the Heavy Naphtha into a reformate stream of hogh
octane number. Heavy Naphtha is complex mixtureof up to 300 hydrocarbons. Thes component
can be categorized as Naphthenes, parafins, olefins and aeromatics. The higher the octane
number of Gasoline it will enhance the efficiency of the engine and reduce the chances of
knocking in the engine, which can be catastrophic in the long range.
In general in a reformer 86 different reactions take place. Which can be categorized into the
following 6 basic types of reaction.
 Dehydrogenation: Naphthenes or cyclic compounds release Hydrogen to form
aromatics.
 Dehydrocyclisation: Paraffins release hydrogen to convert to Naphthenes and
Aromatics.
 Isomerization:Structure of parafins, naphthenes and aromatics altered without
change in molecular weight.
 Hydrocracking: Breakdown of Larger Paraffins and Naphthenes into smaller
Paraffins.
 Hydro aromatization: Conversion of chains into cyclic and aromatic structures.

18. The reactions are catalyst driven. The catalyst used is basically a Rhenium/Aluminum by
metallic catalyst.
The best feature of the reformer is that hydrogen that is required is produced from the reaction
as a byproduct. For each percent hydrogen required, 12.5% more is produced. This excess ratio
enables the refinery to full fill its hydrogen requirement in reformer and Hydrotreater section.
Most of the reactions are endothermic in nature. The catalyst have a SOR (Start of Run)
Temperature of 475 0C to EOR (End of Run) Temperature of 510 0C in the first two reactors, as
most of the reactions here are endothermic. The reactions in the last reactor are exothermic
thus the heating requirement there is very low.
Reformate before rundown is stabilized by stripping LPG components out and have the
required product specs. After stabilizing the Gasoline Reformate is run down as a commercial
grade product.
Reformer unit PFD:
UTILITY UNIT
 Power Plant
 Cooling Tower
 Boiler
 Compressor
 RO Plant ( installed in ORC -2)

19. Crude oil storage capacity
Storage Tanks Information
Sr No. Description
Dimension
(In Meters)
Total Capacity
(M.TON)
1 CRUDE OIL STORAGE TANK 30.48 X 14.63 9,150
2 CRUDE OIL STORAGE TANK 30.48 X 14.63 9,150
3 CRUDE OIL STORAGE TANK 30.48 X 14.63 9,150
4 CRUDE OIL STORAGE TANK 30.48 X 14.63 9,150
5 CRUDE OIL STORAGE TANK 70.00 X 14.63
46,000
6 CRUDE OIL STORAGE TANK 70.00 X 14.63 46,000
THE END