This document appears to be an internship report submitted by Umeshkumar Ladhani detailing his 4-week internship at BYCO Petroleum Pakistan Limited's ORC-2 facility. It includes acknowledgments, an introduction to BYCO, descriptions of the crude distillation process and various other units within the refinery including utilities. The report provides high-level overviews of the different processes within the refinery with a focus on learning during the internship.

1. UmeshKumarladhani
2013
Interbshipreportof internshipsessionaug-sep2013 at ORC-2, from
Umeshkumar ladhani(D-10-Ch-1249),studentof Dawooduniversityof
engineeringandtechnologyKarachi,undersupervisionof Mr.abdul
qadirdal.
BYCO PetroleumPakistanlimited
ORC-2

2. Contents
ACKNOWLEDGMENT
1. INTRODUCTION TO BYCO Oil Pakistan Ltd
2. EHS DEPARTMENT
3. Process Description
I. CRUDE UNIT PROCESS
a) Desalting
b) PRE-Heat Train
c) Furnace
d) Fractionating column
II. NAPHTA HYDRO TREATING UNIT
d) REACTIONS INVOLVED IN HYDROTREATING UNIT
III. GAS UNIT
IV. ISOMERISATION UNIT
4. UTILITIES
a) REVERSE OSMOSIS PLANT
b) COOLING TOWER
C) BOILER
d) DE ARATOR

3. ACKNOWLEDGEMENT
As an internee in BYCO Petroleum is undoubtedly the most learning and
fascinating experience of my life. During my short 4 weeks internship in ORC-2,
I got lots of learning, immense experience and useful social terms. I will
remember BYCO always not just as a refinery but also as a complete institute
with practical, theoretical and with experienced knowledge.
Through this report I would like to thank all the members of BYCO family,
from top leadership to single employee, they all played a vital role during my
internship tenure.
I specially pay my compliments to the following officials
Mr. Faraz Ahmed Sheikh (head of operations)
Mr. Sakhawat Ali
Mr. Sidique Ahmed
Mr. Shoaib Ahmed
Mr. Abdul Qadir Dal
Mr. Farukh iqbal
Mr. Asadullah
Mr. Shams
Mr. Owais
Mr. Noman
MR. Khalil ur rehman
I’m also grateful to all those operators who helped me during my task.
Once again thank you BYCO petroleum Pakistan limited.
Umesh Kumar Ladhani.
D-10-Ch-1249

4. INTRODUCTION
Byco is Pakistan’s emerging energy companies engaged in the
businesses of oil refining, petroleum marketing, chemicals
manufacturing and petroleum logistics. Headquartered in Karachi.
They are serving a mission to fulfill the energy demand within and
beyond borders.
Companies under BYCO umbrella are:
 Byco Oil Pakistan Limited (BOPL)
Oil Refining & Chemical Manufacturing
 Byco Petroleum Pakistan Limited (BPPL)
Oil Refining & Petroleum Marketing
 Byco Terminals Pakistan Limited (BTPL)
Petroleum Infrastructure & Logistics
BYCO is engaged in manufacturing of a wide range of petroleum
products with the objective to achieve sustainable productivity,
profitability and high standards to address the environment, health
and safety requirements.
Byco's ORC-2 has a capacity to refine 1,20,000 barrels a day of
crude oil into various saleable components including Liquefied
Petroleum Gas, Light Naphtha, Heavy Naphtha, High Octane Blending

5. Component, Motor Gasoline, Kerosene, Jet Fuels, High Speed Diesel
and Furnace Oil.

6. Environment, Health and Safety (EHS)
At Byco petroleum Pakistan limited EHS is run under an integrated management
system( IMS) . The basic goal is to develop the company on ethical and
professional basis and be a responsible corporate entity with respect to
Environment, health and safety. As for as the environment is concerned , PAK-
EPA (Pakistan environmental protection agency) keeps a check and balance on
the environmental regulations. The company ensures for the protection,
conservation, rehabilitation and improvement of environment , for the
prevention and control of pollution, and promotion of sustainable development.
STANDARDS
Standards followed at BPPL are:
• Environmental management system(EMS) ISO 14,001
• Quality management system(QMS) ISO 9001
• Occupational health safety assessment series (OHSAS) ISO 18,001

7. PPE’s (Personal Protective Equipment):
Safety features are followed by every worker at the BPPL. All the workers wear
PPE’s for their safety. This includes:
 Safety helmet
 Safety shoes
 Safety cover
 Gloves, Air Filters, Goggles at sensitive areas
 Body Safety Harness at height

8. PLANT SAFETY
Safety is the start of being safe /protected against failure, damage, error,
accidents, harm or any other event. To prevent accidents main causes of
accidents should be known.
TYPES OF HAZARDS
1. Fire and explosion hazards
2. Health and hygiene hazards
3. Electrical hazards
4. Pressure hazards
5. Maintenance
SAFETY EQUIPMENTS
1. Fire alarms
2. Smoke detectors
3. Personal protective equipment
4. Pressure control valves
5. Temperature control valves
6. Level control valves
7. Emergency shutdown valves

9. WORK PERMITS
Hot work permit: includes the work in which sparks are produced
Cold work permit: activates involve working in plant areas
Excavation work permit: including civil work
Confined space entry certificate: e.g. work inside confined space

10. Distillation Process
Crude Distillation Unit (CDU):-
THE CRUDE UNIT PROCESS PRINCIPLES:-
The Crude Unit can be divided into five sections:
1. Desalting Unit
2. Heat Exchangers
3. Furnaces
4. Crude Distillation Tower
5. Kerosene, LGO and HGO Stripper
The crude distillation unit is the first processing stage in the refinery. Here the
crude is separated into five basic streams which are then further processed in
the remainder of the refinery to yield a range of products from LPG to heavy
fuel oil. Separation of the crude is accomplished by vaporizing and cooling the
crude under controlled conditions so that fractions or cuts of the desired boiling
range are obtained. In BYCO these are:
Stream Boiling range 0
F Description
Overheads 0 -320 overhead
Naphtha
No.1 side stream 320-510 kerosene
No.2 side stream 510-680 light gas oil
No.3 side stream 680-750 gas oil

11. Bottoms 750+ reduced crude
FEED:-
The feed to the unit normally consists of predominately Qatar Marine crude.
The unit is designed to handle 115 MBPD. The feed is pumped to the unit from
crude storage by pumps located near the crude tanks.
DESALTING:-
Crude oil often contains water, inorganic salts, suspended solids, and water-
soluble trace metals. As a first step in the refining process, to reduce corrosion,
plugging, and fouling of equipment and to prevent poisoning the catalysts in
processing units, these contaminants must be removed by desalting
(dehydration).
The two most typical methods of crude-oil desalting, chemical and electrostatic
separation use hot water as the extraction agent. In chemical desalting, water
and chemical surfactant (demulsifies) are added to the crude, heated so that
salts and other impurities dissolve into the water or attach to the water, and
then held in a tank where they settle out. Electrical desalting is the application
of high-voltage electrostatic charges to concentrate suspended water globules in
the bottom of the settling tank. Surfactants are added only when the crude has
a large amount of suspended solids. Both methods of desalting are continuous. A
third and less-common process involves filtering heated crude using diatomaceous
earth.

12. PRE-HEAT TRAIN:-
The heat exchangers used in byco is Shell and tube heat exchangers consist of a
series of tubes. One set of these tubes contains the fluid that must be either
heated or cooled. The second fluid runs over the tubes that are being heated or
cooled so that it can either provide the heat or absorb the heat required. Shell
and Tube heat exchangers are typically used for high pressure applications.
A crude oil processing system, comprising:
a plurality of heat exchangers defining a pre-heat train arranged along a crude oil flow
path having an upstream end and a downstream end for progressively heating a flow of
crude oil;
and a furnace for heating the crude oil for processing, wherein the furnace is disposed
at the downstream end of the crude oil flow path at the end of the pre-heat train.

13. FURNACE:-
Furnace is a device used for heating. There are two types of furnaces,
 Vertical furnace (tower furnace)
 Horizontal furnace (box furnace)
In ORC-2 at CDU plant-1 horizontal furnace is in use, in which there are 24
burners, 22 on fuel gas, and 2 on fuel oil.
Crude after pre-heat train at 580 0
f enters in furnace, and after heating it
gives the product of about 7000f.

14. FRACTIONATING COLUMN:-
A fractionating column or fractionation column is an essential item used in the
distillation of liquid mixtures so as to separate the mixture into its component
parts, or fractions, based on the differences in their volatilities.
Crude distillation unit is the soul of any type of refinery.
In byco ORC-2, cdu column contain 37 plates, in which 4 plates of bottom of
stripping section are sieve plates, 4th
one is feed plate or flash zone, and
remaining 33 are movable valve plates.
Different products at different temperatures at different plates are achieved as
mentioned above.

15. NAPTHA HYDRO TREATING UNIT:-
It is a catalytic chemical process which is widely used to remove sulfur, oxygen,
nitrogen and other metal content. This unit is also called Hydro-desulphurization
unit.
The over head stream from plant-1 contain organic impurities i.e. wide range of
organic sulfur compounds, including thiols, thiophenes, organic sulfides and
disulfides, mercuptants and many others.
It is important to remove organic impurities from the overhead stream
containing naphtha, gasoline, LPG and other lighters because these contents are
highly poisonous to the catalyst used in the Plat former unit and Isomerization
unit which is used to increase the octane number.
SURGE DRUM:-
The overheads from the crude column enter feed surge drum. Surge drum is a
vessel used helps in giving proper suction head and it maintains the N.P.H.S. the
water vapors present in naphtha also remove in this vessel. Compressed hydrogen
gas is mix with naphtha before entering the pre heat exchangers train and then
send to the furnace. Furnace:-
The feed is further heated into the furnaces to get the required temperature
for the catalytic reaction in the reactor. At this point the feed almost 95 %
vapors and 5% of liquid and its temperature is about 300-350°C and it was fed
to the reactor.
FIXED BED CATALYTIC REACTOR:-
The reactor used in this unit is Fixed Bed Catalytic Reactor in which catalyst is
used to increase the reaction time. The nature of bed in the reactor is fixed.
The fixed bed comprised of three layers; move from bottom to top there was a

16. bottom layer of ceramic balls of four different sizes. The difference of sizes is
used to increase the residence time and for proper distribution of feed and to
avoid channeling. After this there was a bed of catalyst i.e. Cobalt and
Molybdenum. And at the top again there was a layer of ceramic balls of different
sizes. At top the reactor is vacant up to the certain height for giving the
proper area to spread over the layer of ceramic balls otherwise channeling starts.
The feed stock contains a wide range of organic sulfur compounds, including
thiols, thiophenes, organic sulfides and disulfides and many others. In this reactor
feed stock is converted into H2S, NH3 and water due to sulfur, nitrogen and
oxygen respectively. The reaction is both exothermic and endothermic but the
net result is endothermic as the temperature drop is minute. The important
factor in fixed bad reactor is the catalyst regeneration which was depends upon
pressure drop. The pressure drop across reactor could not exceeds to 1 if it did
then it indicates that the life of catalyst is over and we have to re generate it.
This problem is also occurring if scaling of ceramic balls takes place. If
compressors face sudden electricity dip then pressure in the reactor also drop
due to which carbon starts deposits on the ceramic balls which causes to increase
the pressure difference of reactor.
REACTIONS INVOLVED IN HYDROTREATING UNIT:-
Desulfurization:-
• Mercaptans RSH + H2 RH + H2S
• Sulphides R2S + 2H2 2RH + H2S
• Disulphides RS2 + 3H2 2RH + 2H2S
Deoxidation:-
• Phenol C6H5OH + H2 C6H6 + H2O

17. • Peroxides C7H13OOH + 3H2 C7H16 + H2O
Denitrogenation
• Pyrole C4H4NH + 4H2 C4H10 + NH3
• Pyridine C5H5N + 5H2 C5H12 + NH3
Other reactions include hydrocracking, DE halogenation and hydrogenation. These
reactions are both endothermic and exothermic but the overall effect is
exothermic thereby increasing the temperature slightly. The quantity of sulphur
is reduced from 1200 ppm to <200 ppm. The gases obtained from the reactor
are H2S, ammonia, hydrogen and water vapors which are then removed in
separating vessels.
PFD of NHT unit:-

18. GAS PLANT:-
The purpose of gas recovery plant is to separate the light ends from various
other refining units into specific materials such as propane and butane. The
other function is to remove the light ends from the naphtha fraction of crude
to produce the most useful feedstock for the platformer.
There are four streams fed to the gas plant-naphtha from the naphtha HTU,
the over head liquid stream from the platformer depentanizer, the gas stream
from the distillate HTU stripper.
The purpose of this unit is to separate the ethane and lighter products from
the heavy naphtha. The naphtha from the hydrotreater unit is then fed into
the de- ethanizer column. In this unit ethane and lighter products are
separated from heavy naphtha along with some hydrogen sulphide (H2S). The
top product ethane and methane are used as fuel gas in furnaces and boilers.
The de-ethanizer column operates at an overhead accumulator of below 450psia
at 100oF. The bottom product is C3 and above naphtha.
DE-ETHANIZER:-
The word 'De-ethanizer' stands for the recovery of the ethane from the available
feed. The unit configurations would be different in specific applications. The
ethane from natural gas is recovered in NGL fraction unit in a LNG train i.e.
the demethanizer column bottoms mainly C2+ and very less in C1 are fed to
NGL fractionation train where you separate the these liquids. This is the typical
recovery under the cryogenic temperatures. Even in LNG you find the
substantial quantity of the Ethane.
DE-BUTANIZER:-

19. The bottom product from the De-ethanizer column is then fed into the De-
butanizer column for further separation of lighter products. In De-butanizer the
Butane and lighter products are withdrawn as the top product along with
hydrogen sulphide (H2S). LPG’s and H2S is then send to the amine treatment
plant. Some of this condensate is returned as reflux. The botanizer has a
reboiler, which uses 200 psig streams as the heating medium. The bottom
product from de-butanizer passes into de-isohexanizer.
DE-ISOHEXANIZER:-
The bottom product containing C5 and higher hydrocarbons from the de-
butanizer column is then fed into the de-isohexanizer column. In this column iso-
hexanes and pentanes are separated as the top product along with iso-butane.
This top product is used as the feed for isomerization unit. And the remaining
is bottom product contains C7 and higher hydrocarbons used as a feed
forplatforming unit

20. ISOMERIZATION UNIT:-
Improving C5/C6 naphtha cut octane numbers up to 92 represents an
increasingly applied solution to resolve the evolving gasoline pool equation. The
isomerate product is free of sulfur, aromatics and olefins, making it a premium
gasoline pool blending component. Strengthening regulation towards benzene
content in gasoline result in increased quantities of light naphtha when benzene
precursors are removed from reformer feed stocks.
Feed Preparation:-
Feed from Gas plant is introduced Coalescer for moisture removal & than passed
through heat exchanger trains & finally through Sulfur Guard Bed for removal of
Sulfur. Sodium Zeolite is used in this Sulfur removal. Than feed is passed
through Dryers & Feed Surge Drum & sent in the PENAX unit.
PANEX UNIT:-
The isomerization unit is specifically designed to for the continues catalytic
isomerization of paraffins. The pentane from the de-isohexanizer unit is used as
a feed for the isomerization unit. Water must be removed from feed as water is
poison to catalyst. Reaction takes place in the excess of hydrogen which must
also to be dried. Two reactors are used to convert maximum n-paraffin into i-
paraffin in the penex unit. It is first passed through a filter unit.
MOLEX UNIT:-
The Molex feed is normally pumped to the from the upstream penex stabilizer
bottom, through chloride guard bed. Chloride guard bed is used to remove
chloride from the Molex feed. In Molex unit actually we do the separation
processes.

21. UTILITIES:-
REVERSE OSMOSIS PLANT:-
Reverse osmosis plant
Osmosis is the name of a natural process, in which water with lower TDS would
travel to the water with higher TDS, if they are separated by a semi-permeable
membrane. While in Reverse Osmosis process, the water with higher TDS is made
to travel (under pressure) to the water with lower TDS, if they are separated
by a semi-permeable membrane.

22. Schematics of a reverse osmosis system (desalination) using a pressure exchanger.
1: Sea water inflow,
2: Fresh water flow (40%),
3: Concentrate flow (60%),
4: Sea water flow (60%),
5: Concentrate (drain),
A: Pump flow (40%),
B: Circulation pump,
C: Osmosis unit with membrane,
D: Pressure exchanger
Types of RO scheme:-
It is divided into three main sections:
Primary treatment
Secondary treatment
Tertiary treatment

23. Cooling tower:
Cooling towers are devices which remove heat from a medium and reject this
heat to the atmosphere. The basic principle of cooling tower is that of
evaporate condensationandexchange of sensibleheat.

24. TYPES OF COOLING TOWER
Natural draft cooling tower
Mechanical draft cooling tower
NATRUAL DRAFT COOLING TOWER
In natural draft cooling tower air flow is due to largely difference in density
between the warm air in the tower and the external embient air. It has two
types;
Cross flow NDCT
Counter flow NDCT

25. MECHANICAL DRAFT COOLING TOWER
Large fans to draw air through circulated water. It has further two types:
Forced draft cooling tower
Induced draft cooling tower
APPROACH OF COOLING TOWER
The approach is the difference in temperature between the cooled-water
temperature and the entering air wet bulb temperature. It is outlet temp –
wet bulb temp.
RANGE OF COOLING TOWER
The range is the temperature difference between the water inlet and exit
states. Inlet temp –outlet temp.
WET BULB DEPRESSION
The wet bulb temperature is the difference between the dry-bulb temperature
and the wet-bulb temperature. If there is 100% humidity, dry bulb and the
wet-bulb temperatures are identical, making the wet-bulb temperature equal to
zero in such conditions.

26. BOILERS
A boiler is a closed vessel in which water or other fluid is heated. Two types of
boilers are used in BPPL.
Water tube boiler
Fire tube boiler
DEARATOR
A DE aerator is a device that is widely used for the removal of oxygen and
other dissolved gases from the feed water to steam-generating boilers. In
particular, dissolved oxygen in boiler feed water will cause serious corrosion
damage in steam systems by attaching to the walls of metal piping and other
metallic equipment and forming oxides (rust). Dissolved carbon dioxide combines
with water to form carbonic acid that causes further corrosion. Most DE
aerators are designed to remove oxygen.
THANKYOU.