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SUMMER TRAINING REPORT 2011
(23rd MAY-15th JULY)
INDIAN OIL CORPORATION LIMITED
PANIPAT REFINERY
ATMOSPHERIC AND VACCUM DISTILLATION UNIT
SUBMITTED BY
RAVI VERMA (08112028)
DEPARTMENT OF CHEMICAL ENGINNERING
Dr. B.R. AMBEDKAR NATIONAL INSTITUTE OF TECHNOLOGY
JALANDHAR
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ACKNOWLEDGEMENT
My sincere thanks to Mr.Y.B.Joshi and Mr. Ravi Sharma for allowing me to
do training under their guidance. I am grateful for their cooperation.
I express my sincere gratitude to Mr. K.S.Shukla and Mr. Subhajit Sarkar for
providing invaluable support and guidance.
My acknowledgement especially to Mr.Vikas kashyap (Process Engineer) who
helped me to understand the practical aspects of my project and in giving the
useful data necessary for the project.
The various guidelines and information given to me by Mr. BARDAN LAMA,
Mr. PRATEEK and Mr. GAGAN were of extreme help during project.
I would like to appreciate the time taken out by them for clarifying my doubts
and helping me at various steps.
RAVI VERMA
08112028 ------------------------------
DEPARTMENT OF CHEMICAL ENGINNERING
NATIONAL INTITUTE OF TECHNOLOGY
JALANDHAR
(2008 – 2012)
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CONTENTS
SECTION -1 IOCL
1. An Introduction To INDIAN OIL CORPORATION
2. IOCL PANIPAT
SECTION -2 ATMOSPHERIC AND VACCUM DISTILLATION
UNIT
1. INTRODUCTION
2. PRODUCTS OF UNIT
3. CRUDE AND PRODUCT SPECIFICATION
4. LIST OF EQUIPMENTS
5. PROCESS DESCRIPTION
6. CRUDE DISTILLATION UNIT
7. NAPTHA STABILIZER SECTION
8. NAPTHA SPLITTER SECTION
9. MTO SPLITTER SECTION
10. VACCUM DISTILLATION UNIT
11. LPG AMINE & CAUSTIC WASH SECTION
12. FUEL GAS TRAETMENT SECTION
13. CHEMICALS REQUIRED
14. UTILITIES REQUIRED
SECTION -3 PROJECTS
1. INTRODUCTION
2. FLOW DIAGRAM
3. CALCULATION
4. RESULT
SECTION -4 REFRENCES AND BIBLOGRAPHY
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SECTION 1:
IOCL
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INDIAN OIL CORPORATION
Indian Oil Corporation Ltd. is India’s largest commercial enterprise, with a
sales turnover of Rs.2,85,337 crore and a net profit of Rs.2,950 crore for
the year 2008 – 09. Indian Oil is also the highest ranked Indian company
in the prestigious Fortune Global 500 listing ( 116 to position in 2008).
Indian Oil Company Ltd. established as an Oil marketing entity on 30th
June 1959, and was renamed Indian Oil Corporation Ltd. on 1st September
1964 following the merger of the refining entity ,Indian Refineries Ltd.
Since then, the Indian Oil people with their dedication and determination
have nurtured the integrated downstream petroleum company into India’s
No. 1 company and the country’s largest commercial enterprise . It is the
ceaseless efforts of several generations of the Indian oil family that has
today placed the corporation firmly among the world’s largest corporate ,
with the distinction of being 18th largest petroleum company in the
world .
Set up with a clear mandate for achieving self-sufficiency in petroleum
refining ,pipelines transportation and marketing operations for a nascent
nation set on the path of economic growth and prosperity , Indian Oil is
proud to account for nearly half of India’s petroleum consumption today .
Indian Oil and its subsidies account for 49% petroleum products market
share , 40.4 % refining capacity and 69 % downstream
Sector pipelines capacity in India. The Indian Oil Group of companies owns
and operates 10 of India’s 20 refineries with a combined refining
capacity of 60.2 MMPTA. i.e. 1.2 barrels per day. The Corporation’s cross –
country network of crude oil and product pipelines ,spanning about 9,300
km and the largest in the country, meets the vital energy needs of the
consumers in an efficient, economical and environmental – friendly manner.
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To achieve the next level of growth, Indian Oil is currently forging
ahead on a well laid – out road map through vertical integration -
upstream into oil Exploration & Production and downstream into
petrochemicals and diversification into natural gas marketing, besides
globalization of its downstream operations .
As the leading public sector enterprise of India, Indian Oil has
successfully combined its corporate social responsibility agenda with its
business offerings, meeting the energy needs of millions of people
everyday across the length and breadth of the country , traversing a
diversity of cultures , difficult terrains and harsh climatic conditions . The
corporation takes pride in its continuous investments in innovative
technologies and solutions for sustainable energy flow and economic
viable and environment- friendly products & services for the benefit of its
consumers.
IOCL PANIPAT
Panipat Refinery is the 7th refinery of Indian Oil commissioned in 1998.
Referred to, as country’s technically advanced refinery is situated in the village
Baholi in Panipat District of Haryana. Built at the cost of Rs.3, 868 crore, it has
an installed capacity of 15 MMTPA now. Backed by global, state-of-the-art
technologies from IFP-France, Haldor Topsoe-Denmark, UNOCAL/UOP-USA,
Stone & Webster-USA, and Delta-Hudson-Canada. The refinery is designed for
processing both indigenous and imported crudes. It receives crude oil through
the chaksu-Kamal branch pipeline of the Salaya-Mathura pipeline Vadinar
Gujarat coast to Panipat through a 1339 km long pipeline.
The various products of the refinery are:
01. Liquefied Petroleum Gas
02. Naphtha
03. Motor Spirit
04. Aviation Turbine Fuel
05. Mineral Turpentine Oil
06. Superior Kerosene
07. High Speed Diesel
08. Heavy Petroleum Stock
09. Bitumen
10. Sulphur
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Around 66% of these products are transported through environment-friendly
pipelines, while both rail and road account for 17% each.
Panipat Refinery meets demands of petroleum products not only of Haryana but
also the entire Northwest Region including Punjab, J&K, Himachal,
Chandigarh, Western U.P. and part of Rajasthan and Delhi.
Indian Oil Corporation Limited (IOCL) at Panipat consists of various units.
Among them major once are:
1. Atmospheric and Vacuum Distillation Unit(AVU)
2. Continuous Catalytic Reformer Unit(CCRU)
3. Visbreaking Unit(VBU)
4. Hydrogen Generation Unit(HGU)
5. Resid Fluidized Catalytic Cracking Unit(RFCCU)
6. Once Through Hydrocracker Unit(HCU)
7. Diesel Hydro Desulphurisation Unit(DHDS)
8. Amine Regeneration Unit(ARU)
9. Sour Water Stripper Unit(SWSU)
10. Bitumen Blowing Unit(BBU)
11. Recovery Unit(SRU)
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Atmospheric and Vacuum Distillation Unit(AVU)
SH Steam
Crude Filter Desalter
Furnace
Atmospheric
Column
Unstablised Gasoline
Inter Naphtha
Heavy Naphtha
Kerosene/ATF
Light Gas Oil
Heavy Gas
Oil
SH Steam
Atmospheric Residue
Non-Condensable
Vacuum Residue
Heavy Vacuum
Gas Oil
Light Diesel Oil
Light Vacuum
Gas OilVacuum
Column
AVU is designed to process 6.0 MMTPA Bombay High and Arab Mix crudes in
blocked out operation. AVU, a fully integrated unit, consists of the following
sections. Crude Distillation Unit, Vacuum Treating Units for Fuel Gas, LPG and
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Naphtha. The Unit was mechanically completed in February 1998 and trial
operation of the various sections started in phases starting from May 1998. The
Unit was commissioned on 2nd
October 1998
Continuous Catalytic Reformer Unit(CCRU)
LPG
Reformate
H2 Rich Gas
Fuel Gas
LPG
Absorber
StabliserRecontacting
Drum
Hydrotreater Recycle
Gas Compressor
Hydrotreater
Naphtha
Feed
Seperator Stripper
Reforming
Reactors
Seperator
Purge to
ATU
Recycle Gas
Compressor
H2 Rich Gas
Compressor
Hydrotreated
Naphtha
Storage
M/s. IFP, FRANCE licenses the CCRU. This unit is designed to process 0.5 MMTPA
of SR Naphtha from Arab mix and/or Bombay High crude. This unit consists of
Naphtha Hydro Treating, Catalytic Reforming and Catalyst Circulation and
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Regeneration Sections. Catalytic Reforming is a major conversion process that
transforms low octane Naphtha feed stock to high octane reformate (RON : 98)
for use as a gasoline blending component to make lead free petrol (MS). A rich
hydrogen gas (about 90% purity) and LPG are obtained as valuable by- products. The
reformer can also be run for production of reformate rich in benzene, toluene, and
xylenes (BTX).
Visbreaking Unit(VBU)
SHS
Soaker
AR
Quench
Fractionator
Unstablised
Gasoline
VB Gas Oil
Visbreaking Unit (VBU) is designed to process 0.4 MMTPA Arab mix vacuum
residue. This unit is a soaker Visbreaker, which reduces the viscosity of feed at
lower temperature. The unit was mechanically completed in March 1998 and
the trial operation started in July, 98. The unit was commissioned on 29th
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October 1998.The visbreaker is designed to process 400000 MTPA of Arab mix
vacuum residue from a crude mix of 50:50 Arab heavy and Arab light crudes.
The unit consists of a two pass heater and separation system. The products from
the unit are fuel oil, gasohol, and naphtha and fuel gas.
Products
VB Gas 8200 MTPA
VB Naphtha 13600 MTPA
VB Gasohol 44800 MTPA
VB Tar (350 C) 333400 MTPA
Hydrogen Generation Unit
Recycle H2
Light NaphthaHydro-
Desulphurisat ion
Sulphur
Absorber 1 & 2
Pre-ReformerTubular ReformerMT-Shift
Converter
Pressure Shift
Adsorber
Product H2
Off Gases
The Panipat Refinery Hydrogen Unit is designed to produce 38,000 MTPA of
high purity (99.99%) hydrogen gas Hydrogen is produced in the unit by Steam
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Reforming of Naphtha based on the technology from M/S Haldor Topsoe A/S,
Denmark.
The process for hydrogen generation involves the following four major
steps.
Sulphur removal from Naphtha.
Steam reforming of Naphtha
Medium and low temperature shift conversions.
Hydrogen purification in a PSA unit.
Residue Fluidised Catalytic Cracking Unit
HP
Receiver
Na
ph
tha
Sp
litte
r
LCN
HCN
De
bu
ten
ise
r
Compressor
HCO
Flue Gas
to Stack
Main
Column
Air
Blowe
r
Reactor
RG-2
RG-1
DCO
O/H
Receiver
LCO
LPG
Str
ipp
er
Pri
ma
ry
Ab
so
rbe
r
Sp
on
ge
Ab
so
rbe
r
Off
Gas
Rich
Oil
Feed
Slurry +
HCO
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The demand of the petroleum products in the world is shifting more towards
light distillates because of increasing demand of LPG and Gasolene as a result
of the steady growth in private transportation system and shift towards the
cooking gas in the developing countries. The declining market for fuel oil
coupled with anticipated changes in the future crude quality and the shift in
product demand in favour of light distillate placed and additional emphasis on
upgrading the bottom of the barrel i.e. the heavier residues into more and more
light distillates
Diesel Hydrodesulphurisation Unit
Hydrogen
Make up gas
Compressor
Section
Hydrogen
Reactor
Heater
System
Reactor
Section
Recycle gas
Compressor
Section
Feed
System
Stripper
Section
Naphtha
Stabilizer
Section
HP Amine
Absorber
Section
LP Amine
Absorber
Section Rich Amine
to ARU
Naphtha to
Storage
Gas Oil to
Storage
Separation
Section
Feed
Preheating
System
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The DHDS unit is set up to reduce sulfur content in the diesel and produce
diesel with 0.25% Sulphur.
The unit treats the following gas-oils fractions.
1. S.R.Gas oil
2. Vacuum Diesel
3. Vis-Breaker Gas Oil
4. Total Cycle Oil
DHDS unit has been designed to reduce the sulphur content in High Speed
Diesel to less than 0.05% wt. The process technology for this unit was built
within the record time on LUM SUM TURN key (LSTK) basis by M/s.
L&T. The capacity of the unit is 0.7 MMTPA. The unit was mechanically
completed in March’99 and commissioned on the 12th
July.
Amine Regeneration Unit(ARU)
ARU is designed to process Hydrogen Sulfide rich amine from amine
Absorption units and recover amine after releasing the acid gas to the Sulphur
Recovery Unit. This unit was mechanically completed in February’99 and was
commissioned on 6th
March’99.
Sour Water Stripper Unit(SWSU)
The unit consists of 2 Sour Water Stripping Units, one for the sour water from
the Hydrocracker unit and the other for the sour water from the remaining units.
This unit was mechanically completed in December’98 and was commissioned
on 15th
February’99.
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Bitumen Blowing Unit (BBU)
Bitumen Blowing Unit (BBU) has been designed to produce 3 grades of
Bitumen, viz.: 80-100, 60-70 and 30-49 from vacuum residue of high Sulfur
Crudes. The capacity of the unit is 0.5 MMTPA. This unit was mechanically
completed in March 1998; trial run of the unit was taken in July 1998 and was
commissioned on 12th December 1998.
Sulfur Recovery Unit (SRU)
SRU is designed to process Hydrogen Sulfide rich acid gas recover elemental
sulfur. The unit was designed by M/s. EIL for a capacity of 84tonnes per day
96% recovery efficiency, which has further been revamped to 115 tonnes per
day and 99% recovery efficiency based on the process technology of M/s. Delta
Hudson, Canada. This unit was mechanically completed in March’99 and was
commissioned on 30th March’99.
Other Facilities:
Off sites
The off sites facilities at Panipat Refinery are spread over an area of 115 acres.
There are 77 Storage tanks having storage capacity of 400,000KL Crude Oil
and 830,000KL of Petroleum products. There are 7 nos. of pump stations, a
blending station and connecting pipelines. There are 7 nos. of LPG Horton
Spheres each of 1500KL capacity. The off sites operation is controlled from the
centralized DCS control room of OM&S. The special feature of offsite
operation is that Tank Truck loading (TTL) and Tank Wagon Loading (TWL)
facilities are provided at the Marketing Terminal, which is adjacent to the
refinery. Offsite operation of the Refinery started with the receiving of the first
batch of crude oil in Refinery Storage Tanks on 30th
November’97.
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Thermal Power Station & Utilities
The Power and Steam requirement of the refinery is met from the Captive
Power Plant designed and constructed by BHEL in consultation with NTPC.
Capacity of the power plant is:
Steam Turbine Generator – 3 x 25 MW.
Gas Turbine Generator – 30 MW.
Steam boiler – 3 x 160 T/hr.
Heat Recovery Steam Generator: 125 T/hr.
The first boiler was commissioned in May’97 and first TG was commissioned
in August’97.
Nitrogen Plant
Nitrogen is produce in a cryogenic separation plant by air distillation after
liquefying the same. M/s. BHPV constructed the plant on a turnkey basis. The
capacity of the plant is 800 NM3/hr. The plant was commissioned on
December’97.
Miscellaneous
One raw water reservoir of capacity 200,000KL
Raw water treatment plant of capacity 2100KL/hr.
Four chains of DM Water treatment plant
Compressed air system with 4 nos. of compressors and 3 nos. air drier.
Cooling tower with 5 cells for TPS and 8 cells for process units
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SECTION 2
ATMOSPHERIC AND VACCUM
DISTILLATION UNIT
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INTRODUCTION
Atmospheric, Vacuum and Naphtha Splitter unit of Panipat Refinery is designed
to process 100% Bombay High Crude and 100% Arab Mix Crude (consisting of
light and heavy crude in 50:50 proportion by weight) in blocked out operation
without loss of throughput @ 7.5 MMTPA. Unit is located in an area of 24800
square meters & was commissioned with 6.0 MMTPA in May 1998 and
revamped to 7.5 MMTPA in October 2010. In actual practice various low
sulphur crude and high sulphur crude are being processed since commissioning
of the plant.
AVU is called a mother unit as it provides feed to other secondary units like
hydrogen unit, CRU, HCU, FCC, Bitumen unit and VBU.
In addition to crude processing, AVU also maintains Fuel Gas amine wash
system and LPG vaporiser to maintain refinery fuel gas header pressure.
SECTIONS IN THE UNIT :
a) Crude Desalting section.
b) Preflash section.
c) Atmospheric Distillation section.
d) Stabiliser section.
e) Naphtha splitters for HGU, CCRU and PX feed
f) Naphtha Caustic wash section.
g) MTO splitter section.
h) Vacuum Distillation section.
i) LPG Amine & caustic wash section.
j) Centralised Sour Fuel gas Amine treatment section.
k) LPG vaporiser section.
CAPACITIES :
1) Crude Distillation Unit 7.50 MMTPA
2) Vacuum Distillation Unit. 4.125 MMTPA
3) Naphtha stabiliser. 1.525 MMTPA
4) Pre-topping column. 1.375 MMTPA
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5) MTO splitter. 0.03 MMTPA
0.03 MMTPA production from ATF/KERO stream of Arab Mix with
4000 Hrs. operation.
6) Naphtha caustic wash
C5-90ºC cut. 0.48 MMTPA
90-120º C cut. 0.6MMTPA
S.N
O SHORT
NAME
LONG NAME CUT RANGE º
C USAGE
1. GAS
Fuel gas C1-C2 Internal fuel
2. LPG Liquefied Petroleum
Gas
C3-C4 Domestic/Auto
fuel
3. NAPH Naphtha C5-120 MS Component
4. HN Heavy Naphtha 120-150 HSD
Component
5. KERO Kerosene 140-270 Domestic fuel
6. ATF Aviation Turbine Fuel 140-240 Aeroplanes
7. LGO Light Gas Oil 240/270-320 HSD/
DHDS/DHDT
feed
8. HGO Heavy Gas Oil 320-370 HSD/
DHDS/DHDT
feed
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2. PRODUCTS OF THE UNIT
3 . CRUDE AND PRODUCT SPECIFICATION
SPECIFICATION OF CRUDE :
1) Gravity 30-40 º C API
2) Viscosity 3-24 Cst @ 36 º C
3) Pour point (-) 30 – (+) 30 º C
4) RVP 0.34-0.67 Kg/cm2 (max.)
5) Salt content 165 ppm (max.)
6) BS & W 2.0% vol. (max.)
7) Total Sulphur 0.17-2.35 % Wt.
8) Wax Content 10.68-2.8% wt.
SPECIFICATION OF PRODUCT :
9. VD Vacuum Diesel 370 HSD/
DHDS/DHDT
feed
10. LVGO Light Vacuum gas Oil 370-425 Feed to
HCU/FCCU
11. HVGO Heavy Vacuum Gas
Oil
425-550 Feed to
HCU/FCCU
12. V.SLOP Vacuum Slop 550-560 IFO Component/
feed to RFCCU
13. VR Vacuum Residue 560+ Bitumen/ VBU
feed/ DCU feed /
RFFCU feed
14. C5-90º C cut NAPTHA C5-90 HGU
feed/ISOM Feed
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1) LPG Confirm to IS-4576 to general and
following specifications in
particular.
a) Vapour pressure @ 65º C not to
exceed 16.87 Kg/cm2 (a)
b) Weathering 95% vol. Minimum
at 2º C and 760 mm HG
pressure.
c) Not more than 1% of C5
components.
2) STABILISED NAPHTHA RVP not to exceed 0.7 Kg/Cm2 (a)
3) HN Flash : >15 C
Distillation : 120-140 º C
4) KERO Confirm to IS : 1459-
1974
FBP : 300º C (max.)
Flash : 38º c (min)
5) ATF Flash : 38º C (min)
Freezing : (-) 50º C (min)
Silver strip : Nil
Corrosion.
Density @ : 0.775 to 0.84
6) MTO Confirm to BIS-1440 in general and to
the
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Following specifications in particular.
ASTM D-86 IBP : 145º C
FBP : 200º C
Flash : 38º C
7) LGO Flash : 35º C (min)
Pour : As per instruction.
8) HGO Flash : 35º C (min.)
Pour : As per instruction
Recovery : 90% @360 º C
9) RCO Flash : 150º C
Density : As reported
Recovery : 10% at 370º C
10) Vac. Diesel Flash : >125º C
Pour : (+6) to (+) 18º
Recovery : 90% @360 º
C
11) LVGO CCR :
0.50wt.%max.
12) HVGO Pour : (+) 27 to (+)
42º C
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4. LIST OF EQUIPMENTS:
A. COLUMNS:
1. Crude Distillation column
2. Heavy Naphtha stripper
3. KERO/ATF Stripper
4. LGO stripper
5. HGO stripper
6. Naphtha stabilizer
7. Naphtha splitter
8. MTO Splitter
9. Vacuum Distillation column
10. LPG Amine Absorber
11. Fuel Gas Amine Absorber
A. VESSELS
B. PUMPS
C. FURNACES (Crude furnace, Naphtha Splitter Furnace and Vacuum
furnace)
D. EJECTORS
E. AIR FIN COOLERS
F. AIR FIN COOLER FANS
G. EXCHANGERS
H. REBOILERS
I. DESALTERS (Crude Desalter 1st stage, 2
nd stage and 3
rd stage)
5. PROCESS DESCRIPTION
Crude oil from crude charge pumps is charged to preheat exchanger trains in
two parallel streams.
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1st PREHEAT TRAIN
The first crude stream passes through Crude v/s vacuum diesel CR and
picks up heat from Vacuum Diesel CR coming at 142-166º c. Vacuum
Diesel CR is cooled to 91-99º C, whereas crude is getting heated upto 56-