CHAPTER 1 : BARAUNI REFINERY
1145129/8035-11, GTBKIET, Malout
Barauni Refinery
Barauni Refinery was built in collaboration with Russia and
Romania. Situated 125 kilometeres from Patna, Barauni Refinery was
commissioned in 1964 with a refining capacity of 1 Million Metric
Tonnes Per Annum (MMTPA). It was dedicated to the Nation by the
then Union Minister for Petroleum, Prof. Humayun Kabir in January
1965. After de-bottlenecking, revamping and expansion projects, its
current capacity 6 MMTPA. With various revamps and expansion
projects at Barauni Refinery, capability for processing
high-sulphur crude has been added, thereby increasing not only the
capacity but also the profitability of the refinery.
Barauni Refinery was initially designed to process low sulphur
crude oil (sweet crude) of Assam. After establishment of other
refineries in the Northeast, Assam crude is unavailable for this
refinery. Hence, sweet crude is being sourced from African, South
East Asian and Middle East countries. The refinery receives crude
oil by pipeline from Paradip on the east coast via Haldia. Matching
secondary processing facilities such Resid Fluidised Catalytic
Cracker (RFCC), Diesel Hydrotreater (DHDT), Sulphur Recovery Unit
(SRU) have been added. These state-of-the-art eco-friendly
technologies have enabled the refinery to produce green fuels
complying with international standards. The third reactor has been
installed in the DHDT unit of Barauni Refinery to produce Diesel
that complies with the Bharat Stage-III auto fuel emission norms.
The MS Quality Upgradation project of Barauni Refinery is in full
swing to supply Bharat Stage-III compliant petrol to the
market.
Corporate Overview
Email Print IndianOil is India's flagship national oil company
with business interests straddling the entire hydrocarbon value
chain from refining, pipeline transportation and marketing of
petroleum products to exploration & production of crude oil
& gas, marketing of natural gas and petrochemicals. It is the
leading Indian corporate in the Fortune 'Global 500' listing,
ranked at the 125th position in the year 2010.
With over 34,000-strong workforce, IndianOil has been helping to
meet Indias energy demands for over half a century. With a
corporate vision to be the Energy of India, IndianOil closed the
year 2009-10 with a sales turnover of Rs. 271,074 crore and profits
of Rs. 10,221 crore.
At IndianOil, operations are strategically structured along
business verticals - Refineries, Pipelines, Marketing, R&D
Centre and Business Development E&P, Petrochemicals and Natural
Gas. To achieve the next level of growth, IndianOil is currently
forging ahead on a well laid-out road map through vertical
integration upstream into oil exploration & production
(E&P) and downstream into petrochemicals and diversification
into natural gas marketing and alternative energy, besides
globalisation of its downstream operations. Having set up
subsidiaries in Sri Lanka, Mauritius and the United Arab Emirates
(UAE), IndianOil is simultaneously scouting for new business
opportunities in the energy markets of Asia and Africa.
Reach and Network
IndianOil and its subsidiary (CPCL) account for over 48%
petroleum products market share, 34.8% national refining capacity
and 71% downstream sector pipelines capacity in India.
The IndianOil Group of companies owns and operates 10 of India's
20 refineries with a combined refining capacity of 65.7 million
metric tonnes per annum (MMTPA, .i.e. 1.30 million barrels per day
approx.). IndianOil's cross-country network of crude oil and
product pipelines, spanning 10,899 km with a capacity of 75.26
MMTPA, is the largest in the country. With a throughput of 68.5
million tones, it meets the vital energy needs of the consumers in
an efficient, economical and environment-friendly manner
It has a portfolio of powerful and much-loved energy brands that
includes Indane LPGas, SERVO lubricants, XtraPremium petrol,
XtraMile diesel, etc. Validating the trust of 56.8 million
households, Indane has earned the coveted status of 'Superbrand' in
the year 2009.
IndianOil has a keen customer focus and a formidable network of
customer touch-points dotting the landscape across urban and rural
India. It has 19,463 petrol and diesel stations, including 3517
Kisan Seva Kendras (KSKs) in the rural markets. With a countrywide
network of 36,900 sales points, backed for supplies by 140 bulk
storage terminals and depots, 96 aviation fuel stations and 89
LPGas bottling plants, IndianOil services every nook and corner of
the country. Indane is present in almost 2764 markets through a
network of 5456 distributors. About 7780 bulk consumer pumps are
also in operation for the convenience of large consumers, ensuring
products and inventory at their doorstep.
IndianOil's ISO-9002 certified Aviation Service commands an
enviable 63% market share in aviation fuel business, successfully
servicing the demands of domestic and international flag carriers,
private airlines and the Indian Defence Services. The Corporation
also enjoys a 65% share of the bulk consumer, industrial,
agricultural and marine sectors.
With a steady aim of maintaining its position as a market leader
and providing the best quality products and services, IndianOil is
currently investing Rs. 47,000 crore in a host of projects for
augmentation of refining and pipelines capacities, expansion of
marketing infrastructure and product quality upgradation.
Innovation is key
IndianOil has a sprawling world-class R&D Centre that is
perhaps Asia's finest. It conducts pioneering work in lubricants
formulation, refinery processes, pipeline transportation and
alternative fuels, and is also the nodal agency of the Indian
hydrocarbon sector for ushering in Hydrogen fuel economy in the
country. The Centre holds 212 active patents, with over 100
international patents.
Some of the in-house technologies and catalysts developed by
IndianOil include the INDMAX technology (for maximising LPGas
yield), OilivorousS bio-remediation technology (extended to marine
applications too), Diesel Hydro DeSulphurisation (DHDS) catalyst, a
special Indicat catalyst for Bharat Stage-IV compliant Diesel,
IndVi catalyst for improved distillate yield and FCC throughput,
and adsorbent based deep desulphurisation process for gasoline and
diesel streams Redefining the horizon
Fig. 1.6 : Refining
In Petrochemicals, IndianOil offers a full slate of products
including Linear Alkyl Benzene (LAB), Purified Terephthallic Acid
(PTA) and an extensive range of polymers. IndianOil holds a
significant market share of LAB in India and exports to 19
countries. It is also one of the largest suppliers of Mono-Ethylene
Glycol (MEG) in the domestic market clocking a sales volume of 151
TMT during 2010-11. Execution of a state-of-the-art 120,000 tonnes
per annum Styrene Butadiene Rubber (SBR) unit is underway at
Panipat. The SBR unit is expected to further strengthen IndianOils
presence in the speciality petrochemicals sector.
Fig. 1.7 Refinery Night Vision
In Exploration & Production, IndianOil's domestic portfolio
includes 11 oil and gas blocks and 2 CBM blocks in India including
2 blocks as part of a consortium under NELP-VIII (blocks
GK-OSN-2009/1 and GK-OSN-2009/2). The overseas portfolio includes
ten blocks spread across Libya, Iran, Gabon, Nigeria, Timor-Leste
and Yemen. Exploration activities are at various stages of
progress. In addition, as part of consortium, IndianOil has been
awarded Project -1 in the Carabobo heavy oil region of Venezuela.
To boost E&P activities, IndianOil has incorporated Ind-OIL
Overseas Ltd. a special purpose vehicle for acquisition of overseas
E&P assets in partnership with Oil India Ltd.
Fig. 1.8 : Project-1
Natural Gas marketing is another thrust area for IndianOil with
special focus on City Gas Distribution (CGD) business. The
Corporation has entered into franchise agreements with several CGD
players to market Compressed Natural Gas through its retail
outlets. During 2010-11, gas sales grew by an impressive 20.7% to
2.3 million tones from 1.91 million tones in the previous year.
IndianOil's joint venture with GAIL India Ltd. - Green Gas Ltd.
is authorised to take up city gas distribution in Agra. A long term
gas supply agreement has been signed with NTPC. IndianOil is
setting up a 5 MMTPA LNG import, storage & regassification
terminal at Ennore (outskirts of Chennai). This LNG Terminal would
be first of its kind on the East Coast of India.
Furthermore, in consortium with GSPC, HPCL and BPCL, IndianOil
won gas pipeline bids for Mallavaram to Bhilwara and Vijaypur via
Bhopal Mehsana to Bhatinda and Bhatinda to Jammu and Srinagar.
ABOUT BARAUNI REFINERYIOCL is one of the largest public sector
organization in india.The BARAUNI refinery is one of the refinery
run under IOCL. The BARAUNI refinery situated in the oil town of
BARAUNI in Assam is the oldest refinery in Asia. The credit for
setting up of this refinery goes to the British officers serving in
Assam,who found traces of oil in river water in1828.However the oil
well could be developed only at Naharpong, Assam. On 19th october,
1899,oil was made to struck successfully at the depth in BARAUNI.In
1901,the refinery was comissioned.It was initially under the
control of British and was taken over by the Burmah Oil
Company.Later on, this came under Assam Oil Division. The refinery
with an installed capacity of 0.5 MMTPA has been running ever since
1923 with old and absolute technology.It was nationalized in
1981and the planned modernization programme is embarked on. Since
then the refinery has undergone a lot of changes. Some of the older
plants have been placed by modern technology. This enhanced the
capacity of the refinery to 0.65 MMTPA.
The main units of refinery are CDU (Crude Distillation Unit) and
one DCU (Delayed Cocking unit) and coke calcinations unit
AVU(Atmospheric vacuum unit),ETP(Effluent Treatment plant),LDU(LPG
Dispatch unit) etc. The products of the refinery are- Naphtha, LPG,
Motor Sprit., aviation turbine fuel (ATF), superior kerosene oil
(SKO), High speed diesel oil (HSD), Light Diesel oil (LDO) and
petroleum cokes. It is the first refinery to produce Lead free
motor sprit.
The units in the petroleum sectors are- xylene plant, dimethyle
terepthalate plant and fiber plant.
CRUDE OIL DISTILLATION OIL
INTRODUCTION
The Crude Distillation Unit of Barauni Refinery was commissioned
in January 1962 with a refinery capacity of 0.75MMTPA. The capacity
increased to 0.85 MMTPA after a major revamp in 1986. The capacity
has been further increased to 1.15MMTPA after carrying out few
process debottle necking and desalter commissioning. Another major
revamp took place in August 2000 to increase the refinery capacity
to the present 1.3 MMTPA of Bihar mix crude.
The unit receives crude oil from Oil India Ltd. And ONGC and
distillate it to the following products,
1. Fuel gas
-Fuel for heaters
2. Light Gasoline
-Feed stock for LPG & NSF / Isosiv
3. Heavy Gasoline
- Feed stock for NSF
4. SR Kero- I/II
-Feed stock for Hydrotreater
5. SR Gas Oil
- Feed stock for Hydrotreater
6. RCO
-Feed stock for DCU
Feed through put
NORMAL: 3360 TONNES PER DAY
FREQUENCY OF SHUTDOWN
DESIGN RUN LENGTH: 2 YEARS.
PRESENT RUN LENGTH: 4 YEARS
PROCESS FLOW SYSTEM
Preheat Train before Desalter
The crude from battery limit is pumped by pump P-1/1A at about
15.8 Kg/Cm2g through a preheat train where it is heated by,
prefactionator overhead vapors , RCO , SR Kero-II, SR Gas Oil , SR
kero-II and RCO to a temperature of 130(C before entering the
desalter .
Desalter V-101
In the desalter, wash water and crude are mixed. In the presence
of an electric field, the salt in crude dissolves in water, which
is then separated from the oil. The effluent water preheats the
incoming wash water in E-101 before being sent to desalter wash
water vessel. The desalter pressure is maintained at about 13.0 to
15.0 Kg/cm2g.Pretopping Column (CL-1)
The purpose of this column is to remove the SR light gasoline
(IBP to 110(C cut point on TBP) from overhead and reduce the load
on the crude column CL-2.
Preheat train at CL-1 bottoms
The topped crude from CL-1 bottoms is pumped by pumps P-2/2A to
exchangers S-16/S-9D in series, where it is heated by SR Gas Oil
Circulating Reflux (SRGO CR). It then passes to S-21 where it is
heated by Reduced Crude Oil (RCO) to about 245.9(C. At this
temperature pre topped crude enters Atmospheric furnace (C-1A).
CL-1 bottom level is maintained by LIC-003, which operates LV-1334
located on the feed line to CL-1. FI-1137 provided on P-2/2A
discharge line provides the flow rate of pretopped crude.
Atmospheric Furnace (C-1A
The purpose of the Atmospheric furnace is to provide the heat of
vaporization of hydrocarbons lighter than RCO in the pretopped
crude for fractionation in column CL-2.
AIRPREHEATING SYSTEMThe purpose of this system is to recover
heat from hot flue gas so as to increase the efficiency of the
furnace to about 90%. Hot flue gases exiting convection section of
heater are routed to top of air pre heater and flown downwards
preheating the air and improving the thermal efficiency of
heater.
The air preheater consists of 2 sections:
A. Cast APH
B. Glass APH
Main fractionating cloumn CL-2:-The purpose of this column is to
separate the preflashed crude into saleable products by
distillation.
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