The BGR refinery in Bongaigaon, India has a capacity of 2.35 MMTPA and receives crude oil from Assam, Ravva in Andhra Pradesh, and imports. It has two crude distillation units (CDUs) that produce products like LPG, naphtha, diesel, and fuel oil. The CDU consists of sections like preheat trains, desalter, furnace, fractionator, stabilizer, and naphtha splitter. The refinery also has units like delayed coker and catalytic reformer to further process products from the CDUs.

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