Refinery internship

1. INTERNSHIP
PRESENTATION
INSTITUTE OF CHEMICAL TECHNOLOGY –
INDIAN OIL CAMPUS

2. About Indian Oil
 Formed in 1964 , merging of Indian
Refineries and Indian Oil Company Ltd.
P.A.Gopalakrishnan , 1st Chairman
 2010, Maharatna PSU
 11 refineries , Combined refining capacity
is 80.7MMTPA I.e. 33% of domestic
refining capacity
 14,189 cross country pipeline with 94.8
MMTPA cumulative capacity , 49% share
in crude & product pipeline
 2 SPM at Vadinar & 3 SPM at paradip
 16 new grades of crude processed ,11 of
US origin (2017-2018)

3. PANIPAT REFINERY
 Seventh refinery , Technically most
advanced refinery complex
 Total capacity – 15 MMTPA , plan to
augment to 25 MMTPA
 Major secondary units are CRU ,
OHCU , VBU ,BBU etc.
 1st refinery to switch over from BS-III to
BS – IV and now supply of more
ecofriendly BS-VI to NCR, Delhi
 Refinery houses PX-PTA plant and
Naphtha Cracker complex

4. PANIPAT REFINERY EXPANSION PROJECT
 Indian oil has doubled the Panipat refining capacity from 6
MMTPA to 12 MMTPA in 2006 and further augmented its
capacity to 15 MMTPA in 2010.
 Panipat refinery (PR)was designed to process low Sulphur
crude and Panipat refinery expansion project was designed to
process high Sulphur crude.
 The types of crude being processed by Panipat refinery are:
 i)Low Sulphur: Quaiboe, Boney light, Escravos, Furcados
 ii)High Sulphur: Kuwait, Iran Mix, Basrah light, Upper
Zakhum, Suez mix, Furrial etc

5. PIPELINES
 14,189 km long crude oil , petroleum product and gas pipeline
 94.79MMTPA of oil & 9.5MMSCMD of gas (Total processing capacity)
 Safest , cost-effective , energy efficient and environment friendly mode of
transportation
 4 product pipelines – 1)PRPL
2)PAJPL
3) PBPL
4)PBATF
 Panipat-Jalandhar LPG pipeline – 273km pipeline
 Intermediate delivery station for LPG bottling plant at Nabha (Patiala)

7. CRUDE OIL
 85% of crude oil is imported by
India and aims to bring down by
67% by 2022
 Crude oil reserves – 604.10 MT
(2017)
 Crude oil is carried by VLCC via
sea only
 SPM (Single point Mooring )–
Floating buoy for handling of liquid
cargo
 Indian oil operates 2 SPM at
Vadanir & 3 SPM at paradip for
transferring crude oil

8. ATMOSPHERIC AND VACUUM DISTILLATION UNIT
 AVU = CDU(CRUDE DISTILLATION UNIT) +
VDU( VACUUM DISTILLATION UNIT)
 Capacity = 6 MMTPA of Arab Mix crude (
50:50; AL:AH). Check crude : QUAIBOE
 Distillation is the most primary process that is
used for separation of the components of
crude oil due to the varied boiling point
temperature.
 Major units :
 1) Desalter
2) Preheat trains and Flash vessel
3) Atmospheric Heater
4) Atmospheric column
5) Vacuum heater
6) Vacuum column

9. CRUDE DESALTING
 Desalting consists of three major process
•Heating
•Mixing
•Settling
 In desalting , there is formation of emulsion
of oil and water
 Demulsification of emulsion using strong
electric field(A.C).
 Two stage desalting operation and
countercurrent mechanism of desalted
water

10. ATMOSPHERIC DISTILLATION COLUMN
 55 trays, 6 at the bottom are the bottom stripping
section of the column.
 OVHD circuit for removal of Gases and Light
naphtha.
 4 side draws and 3 Refluxes
 Major products of atmospheric column are :
1) Fuel gas and LPG
2) Light Naphtha
3) Heavy naphtha
4) kerosene/ ATF
5) Light Gas Oil
6) Heavy Gas Oil
7) Reduced Crude Oil( RCO+)

11. VACUUM DISTILLATION COLUMN
 RCO from atmospheric column is passed
through vacuum heater before being sent
to vacuum column .The feed from
vacuum heater is send to the vacuum
column at the flash zone above tray #6.
 The vacuum heater flash zone pressure
is at 60-70 mm of Hg and temperature is
398.7/382˚c for AM crude or Quaiboe
crude.
 The various products obtained from
vacuum column :
1) Vacuum diesel
2) Light vacuum Gas Oil
3) Heavy vacuum Gas Oil
4) Vacuum residue
5) Vacuum wax and slop

12. DIESEL
HYDROTREATING
UNIT(DHDT)
 To meet the BS-IV/BS-VI diesel requirement (
minimum cetane number 51)
 Feed – LGO(CDU) at 240-320°c
VD(VDU) AT 370°C , LCGO(DCU)
 Capacity-3.5MMTPA , Licensor – Axens
 Catalyst – Ni – Mo oxides
 Main reactions are hydrodesulphurization ,
hydrodenitrifiaction , Aromatic and olefin
saturation
 Use of two catalysts in a single reactor.

13. PACKINOX
 Ideal for demanding heat recovery duties in processes with high pressure and
temperature
 Low CAPEX , superior hydraulic effiiciency
 Large heat transfer bundle inside pressure vessel
 Heat transfer inside bundle- counter current flow
 Top & bottom manholes for maintainance

15. HYDROCRACKING UNIT(HCU)
 PURPOSE:
The process objective of Hydrocracker unit (HCU) is to produce highest
quality and quantity of High-speed Diesel and LPG products from gas oil feed stocks,
 UNIT CAPACITY:-
The design capacity for the Hydrocracker is 1.7 MMTPA. The feed to the unit is
a mixture of:
 Vacuum Gas Oil (VGO) from Vacuum distillation column.
 Heavy Coker Gas Oil (HCGO) from Delayed Coking unit.
 Heavy Gas Oil (HGO) from Atmospheric distillation column

16. PROCESS:-
 HCU mainly consist of 2 units
Reaction and fractionator section.
 Reactors are of 2 type :-
Hydrotreating,Hydrocracking rxn.
 In the first reactor, which has three
beds, predominantly feed
demetallising and hydrotreating
reactions take place and in the
second reactor, which is having two
beds,.

17. HYDROTREATING RXN:- HYDROCRACKING REACTION:-
Cracking Reaction
• Saturated Paraffins cracked to form lower
molecular weight olefins and paraffins
Isomerization Reactions
• Isomerisation provides branching of alkyl
groups of paraffins and opening of naphthic rings
• Condensation Reaction

18. FRACTIONATION SECTION:-
 The liquid hydrocarbons recovered in Hot and Cold Flash drums of the Reaction
section are steam stripped of their light gaseous components in the Stripper
Column. The vapors recovered in the Stripper flow to a Sponge Absorber Column
 From here it is sent to side strippers from which diesel, petrol are separated.
 This is how a 2 reactor HCU works.
 This section strips out LPG sent for mine treatment.

19. HGU (Hydrogen Generation Unit):
 To generate hydrogen (99.9%) for the downstream hydro processing units
like hydro cracker and DHDT
 Main sections in HGU:
• Pre desulphurization unit: To remove catalyst poison like Si, S and Cl
• Hydro Desulphurization: Removing Sulphur in presence of Hydrogen.
• Reformer section: expensive section filled with Catalyst R67-7H
Reactions: CH4 + H2O CO + 3H2 (ΔH = +ve)
CO+ H2O  CO2 + H2 (ΔH = -ve)

20. Hydrogen Generation Unit
• Pre reformer section: A adiabatic reactor and a singe bed reactor
catalyst: RKNGR
Reactions: CnHm + nH2O  nCO + (n+m/2) H2 ( ΔH = +ve)
CO+ H2O  CO2 + H2 (ΔH = -ve)
CO + 3H2  CH4 + H2O (ΔH = -ve)
• Gas concentration section
• Gas purification section:
Pressure Swing Adsorption

21. Pressure Swing Adsorption
 Principle: Difference in pressure to remove impurities
 Aim: To produce 99.9% pure Hydrogen.
 Operates at High pressure
 12 Beds in pair.
 Runs on predesigned software taking in information.
 In pairs Equalization takes place:
Recovery of hydrogen takes place in
one and removal of impurities takes place in another bed.

22. Motor spirit Quality
upgradation(MSQ)
 BS-IV(RON min-91,MON-81)
 Feed: Naphtha(FCC+CCRU+AVU)
 Four units in MSQ
NHT
LICENSOR
UOP,USA
CAPACITY
410TMTPA
PENEX UOP,USA 400TMTPA
RSU AXENS,FRANCE 470TMTPA
FCC-GDS/PRIME G+ AXENS,FRANCE 370TMTPA

23. • Hydrotreat SR-Naphtha.
• Metal impurities(in ppb in
naphtha) removed.
• PENEX catalyst
poisons(sulfur,O2,NH3,halide)
removed from light naphtha.
NHT(Naphtha
Hydrotreating)
FEED: SR-Naphtha from NSU-1&2.
Reactor pressure:30-35kg/cm sq.
Inlet temperature- 3150 C

24. • To concentrate the benzene and its
precursors in light reformate which is
further routed as feed to penex unit
by splitting the CRU reformate into
light and heavy reformate.
• Heavy reformate sent directly for
MS blending.
RSU(Reformate
splitter unit)
Feed-reformate ex-CRU is feed for
unit.
Designed for two cases-
• Case A-low benzene feed
• Case B-high benzene feed.

26. PENEX
• Penex-1.to increase the octane number of
hydrotreated naphtha
2.To reduce the benzene level in the light
reformate
e.g. 1.C5H12(61.8ron) C5H12(Methyl
butane 93ron)
FCC-
GDS(PRIME
G+)
• Feed-FCC gasoline is the main feed for
the unit .the light Coker naphtha ex DCU
and pyrolysis gasoline ex-Panipat
naphtha cracker project are also part of
feed.
• Process-
• Selective hydrogenation unit
• Gasoline splitter unit
• Hydro-desulphurization unit

27. Naphtha Cracker Unit:
 Largest Operating Cracker unit
 Downstream units: Polypropylene, SWING (HDPE & LLDPE), MEG
 Production: 800 TTPA ethylene and 660 TTPA of Propylene.
 Cracking: 1.Hydrocracking
2. Catalyst cracking
3. Steam Cracking
 Feed: Liq Naphtha & C2 C3
 Products: H2 , Methane, Ethane, Propane, C4 mix.

28. POLYPROPYLENE UNIT
 Two production lines of 300KTA - "SPHERIPOL" technology , Basell (Italy)​
 Catalyst : Ziegler – Natta , Co – Catalyst : TEAL
TEMPERATURE : 70 - 72°C
PRESSURE: 40 Kg

29. SWING UNIT
LLDPE/ HDPE swing plant of 350 KTA capacity based on Sclairtech
Solution polymerisation technology of Nova Chemicals, Canada.
Catalyst :-CAB and CAB-1 they are the mixture of vanadium
oxychloride and titanium chloride in varied ratio, Ziegler Natta.
Solvent-cyclohexane
Ethylene is the monomer and butene is comonomer .

30. MONOETHYLENE GLYCOL
 Capacity-produce 300 KTA fiber grade MEG of which
275KTA MEG,17KTA DEG,8KTA TEG
 Uses – MEG -: Coolant, PET bottles, X-ray films
DEG-: Dyes, Paints, Ink etc.
TEG-: Solvent . Reaction of two types-
 1. desirable-C2H4 + ½ O2C2H4O + H2C2H4O2
 2.undesirable- C2H4 + 2O22CO2 + 2H2O
DEG is made from MEG and ethylene oxide.
TEG from DEG

31. Technical services
Process
monitoring
Planning and
coordination
Energy
conservation
Process
projects
Offsite and
automation

32. Sulphur recovery unit(SRU)
Objective-reduce SO2 emission by
recovering sulphur from aminge
acid and sour gases produced
during various hydrotreating
process
feed-amine acid gas and sour acid
gas
Operating conditions-
temp range-195-320 deg c
Pressure-0.56 kg/cm2
 Chemical reactions in SRU
Claus reaction-main reaction (partial
oxidation in main burner is:
H2S + 3O2 SO2+H20+Heat
Major part of residual H2S combines with
SO2 to form sulphur acc. To eq. reaction-
2H2S+SO2 3S2+2H2O-Heat
This reaction known as Claus ,sulfur is
formed in vapour phase in main burner
and combustion chamber.

33. OIL MOVEMENT &
STORAGE

34. DYKE HVLRM
SPRINKLER FOAM COMPRESSOR
SYSTEM

35. Quality Control(QC LABS)
 A system of maintaining standards in
manufactured products by testing a
sample of the output against the
specification.
 In QC we saw variety of machines
GC, element analysing instruments ,
ICAP-MS,ED-XRF,WD-XRF.
 Kinematic Viscosity:-Kinematic
viscosity is the measure of the
inherent resistance of a fluid to flow
when no external force is exerted

36.  FLASH Point:- Lowest temperature at
which vapours of the material will
ignite, when given an ignition source.
 2 instruments:- ABAL,PMCC .
 Abel is used for low range while Pmcc
is used for high range.
We even saw specifications of many
products ,their preliminary tests. for ex:-
weathering in LPG.

37. PADC(PRODUCT APPLICATION DEVELOPMENT CENTER)
 The Laboratory building is designed to
take on an Iconic position in the refinery
complex, signifying the focus on research
and the Future.
 BLOW MOULDING :- Process of
forming a molten tube and placing the
parison or preform within a mould
cavity.

38.  ROTO MOULDING:-A heated hollow
mould which is filled with a charge
material.
 It is then slowly rotated causing the
softened material to disperse and
stick to the walls of the mould.
TUBULAR QUENCHED POLY PROPYLENE:-
• The resin is extruded & the molten material in form of
tube comes out of the circular die.
• Cooling is done
• Film is subsequently collapsed, passed through drying
unit and finally rolled up

39. THANK YOU