IOCL_Crude Distillation Unit

1. SUMMER TRAINING
(IOCL BONGAIGAON)
Submitted By
Ashok Paliwal
12210008, CH 407
IDD 4th year, Chemical

2. INDUSTRY (IOCL) OVERVIEW
 Established in 1964
 Refining capacity : 65.7 MMTPA ( 1.31 million barrels per day)
 Refineries at Barauni, Gujrat, Mathura, Guwahati, Bongaigaon, Panipat, Haldia

3.  Commissioned in February 1979 as BRPL
 The company became a subsidiary of IndianOil (IOC) on 29 March 2001.
 Designed by Engineers India Ltd.
 Capacity: 2.35 MMTPA (1.5 MMTPA Ravva Crude , 0.85 MMTPA Assam Crude)
 CRUDE OIL SOURCE:
 Assam crude(Sulphur 0.3%), Ravva Crude (Sulphur 0.1%, from the Ravva oil field of Andhra Pradesh) & Imported
Crude (from Nigeria , Indonesia)
 Imported crude oil is received through Haldia – Barauni crude pipeline up to Barauni & from Barauni to BGR by
reverse pumping through oil pipeline.
 PRODUCTS:
 LPG ,Naphtha, MS (Euro-III), Kerosene, HSD(High Speed Diesel), LDO(Light Diesel Oil), LVFO (Light Viscosity Fuel
Oil),LSHS(Low Sulfur Heavy Stock).
BGR Refinery

4. BGR AT A GLANCE
1.CRUDE DISTILLATION UNIT (CDU)
 Capacity: 1.35 MMTPA (1ST UNIT) , 1.00 MMTPA (2ND UNIT)
 Products: L.P.G. ,Straight Run Naphtha ,Reformer Feed Naphtha, Raw Kerosene and Diesel Reduced
Crude Oil (RCO)
2. Delayed Coker Unit(DCU)
 Capacity: 500000 TPA
 Function: Convert crude oil into fuel gas , LPG ,Naphtha, Gas Oil , Fuel Oil & RCO
3. CATALYTIC REFORMER UNIT (CRU)
 Capacity: 160,000 MTA
 Feed: Reformer Feed Naphtha

5.  BGR has 2 CDU units
 Capacity: 2.35 MMTPA
 CDU Unit Consist of Following Sections:
 Crude preheat train and Desalter
 Fired heater
 Crude Distillation Section
 Stripper
 Stabilizer
 Naphtha Splitter
 LPG Wash Section
Crude Distillation Unit

7. 1.Storagetank:
 No of tanks : 7
 Type: Floating Head
 Capacity of tank :20,000 kl
2. Pump:
 Centrifugal Pump
 Pressure : 55 Kg/ cm2
3. Preheat exchanger:
 Series of shell & tube heat exchanger
 Crude oil is preheated up to about 130 °C
 Hot medium: RCO
 Cold medium: Crude Oil
Crude Preheat Train & Fired Heater

8. 3.ELECTRIC DESALTING :
 The desalter is an electrostatic coalesce used for purification of crude from sludge, salts and
corrosion inducing salts
4. 2nd Preheat Exchanger:
Desalted crude oil heated up to about 223 -227 °C
Hot medium: LVFO
Cold medium: Desalted crude oil
5. Furnace:
 Type: Natural draft , vertical cylinder , two passes, with convection and radiation section
 Has 12 burners.
 Preheated crude oil heated to about 358 0C

9. Desalter
 Water Washing
 Heating
 Coalescence
 Settling Rate

10. CRUDE DISTILLATION & STRIPPERS
 Height of Distillation column: 50m
 Number of Trays: 38
 Feed from the fired heater enters the column under tray #5
Fractionator’s :
 Temprature:350 °C
 Pressure :1.3 Kg/cm2
Products :
 Distillate
 Bottom Products

11. Overhead:
 Overhead vapors goes to the overhead condenser at about 142 °C &
 Condensate is collected in reflux drum
A part of this condensate is sent to the crude column as top reflux & balance quantity goes as Stabilizer
feed
Bottom Product:
 Reduced crude oil
Products Withdrawn Temp Tray No
Kero I 225 23
Kero II 260 15
Gas Oil 309 9
Distillate

12.  Column has 30 trays
 Top Temp: 65°C
 Top Pressure: 10 Kg/cm2
 The purpose of stabilizer is to stabilize naphtha by separating out liquefied
petroleum gas (LPG) & others C-4 components
 Kero II CR is used as heating medium for stabilizer reboiler
 LPG withdrawn from Stabilizer reflux drum is first washed with caustic and then
washed with water and then is sent to Horton sphere for storage
Stabilizer

13.  The stabilized naphtha is further split into light naphtha (50-110 °C) and heavy naphtha
(110-180 °C) in Splitter-I
 Splitter-I bottom is further split into reformer feed naphtha (110-147 °C) and Kero
component
 Reboiler heating media for Splitter-II is reduced crude oil from main fractionator
column bottom
Naphtha Splitter

14. CDU 1 v/s CDU 2
CDU I CDU II
Natural Draft type furnace Forced draft type furnace
Number of burners 11 Number of burners 8
Fuel consumption 1.45% of the throughput Fuel consumption of 1.35% of throughput
Capacity 370 Kg/hr Capacity 450 Kg/hr
Double pass furnace Single pass furnace
No of preheat exchanger 11 No of preheat exchanger 14