The document summarizes various units at IOCL Paradip including:
1. An AVU/SRLPG unit that fractionates crude oil into distillate and feedstocks.
2. A CDU, VDU, and naphtha stabilizing section that further fractionate crude distillate into products like kerosene and gas oil.
3. A DCU that upgrades vacuum residue into products like naphtha, gas oil and coke.
4. An alkylation unit that produces high octane alkylate fuel blending component from olefins and isobutane.
5. A butamer unit that produces isobutene needed for the alkylation unit.
6
The document summarizes various units at IOCL Paradip including:
1. An AVU/SRLPG unit that fractionates crude oil into distillate and feedstocks.
2. A CDU, VDU, and naphtha stabilizing section that further fractionate crude distillate into products like kerosene and gas oil.
3. A DCU that upgrades vacuum residue into products like naphtha, gas oil and coke.
4. An alkylation unit that produces high octane alkylate fuel blending component from olefins and isobutane.
5. A butamer unit that produces isobutene needed for the alkylation unit.
6
The document summarizes various units at IOCL Paradip including:
1. An AVU/SRLPG unit that fractionates crude oil into distillate and feedstocks.
2. A CDU, VDU, and naphtha stabilizing section that further fractionate crude distillate into products like kerosene and gas oil.
3. A DCU that upgrades vacuum residue into products like naphtha, gas oil and coke.
4. An alkylation unit that produces high octane alkylate fuel blending component from olefins and isobutane.
5. A butamer unit that produces isobutene needed for the alkylation unit.
6
The document summarizes various units at IOCL Paradip including:
1. An AVU/SRLPG unit that fractionates crude oil into distillate and feedstocks.
2. A CDU, VDU, and naphtha stabilizing section that further fractionate crude distillate into products like kerosene and gas oil.
3. A DCU that upgrades vacuum residue into products like naphtha, gas oil and coke.
4. An alkylation unit that produces high octane alkylate fuel blending component from olefins and isobutane.
5. A butamer unit that produces isobutene needed for the alkylation unit.
6
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3.
Various Units of IOCL Paradip:
3.1. AVU/SRLPG UNIT:
Design capacity: 15MMTPA Licensor: Open art Unit by FWEL Unit Objective: To provide a primary separation of crude oils to produce straight run blend stocks or distillate and feed stock for other downstream process units. Feed Source: . Basarah light and Oman export . Kuwait and Maya crude Product Destination:
CRUDE DISTILLATION UNIT:
Desalted crude is pre-flashed and the liquid part is sent to the distillation column via a crude charge heater, where it combines with the pre flashed vapor. Distillate side stream products kerosene, LAGO and HAGO from the crude column are stripped to improve fractionation. The kerosene is withdrawn as kerosene/ATF product whereas light atmospheric gas oil is sent to DHDT. The overhead gas and naphtha oil streams are send to naphtha unit. Atmospheric residue of the CDU is the feed to the VDU.
Vacuum Distillation Unit:
Atmospheric residue is the feed to vacuum distillation column after heating in vacuum charge heater. Vacuum is maintained in the column by an ejector system. It fractionates the feed into an overhead stream, four side cuts namely vacuum diesel to DHDT, light and heavy VGO-HDT, recycle streams and vacuum residue. The recycle stream is taken back to inlet of the crude heater, which is used to pre heat the feed. The vacuum residue is steam is taken back to minimize cracking .Now the VR is routed to DCU as its feed.
NAPTHA STABILISING SECTION:
The vapor from crude column overhead receiver is routed through a compressor to a re-contractor drum via air cooler and condensed Naphtha from re-contractor drum along with Naphtha side cut stream from CDU enters the stabilizer, stabilized Naphtha is drawn from bottom.
3.2. DCU UNIT
Design capacity: 4.4 MMTPA Unit Objective: Upgradation of vacuum residue to more valuable product Feed source: . Vacuum residue from AVU . CLO from FCCU
Product Destination: . LPG to FCC LPG treater . Light naphtha to FCC . Heavy naphtha to NHUT . LCGO to DHDT . HCGO to VGO HDT . coke to coke pit
PROCESS DESCRIPTION: Petroleum is a mixture of pre dominantly hydrocarbons. The mixture contains some very high molecular weight molecules that will not vaporize even at the low pressures and relatively high temperatures in vacuum distillation units. A number of procedures are available to upgrade these residues to more valuable products such as transportation fuels. These include vis-breaking, coking, fluid catalytic cracking, hydro Vis breaking and catalytic hydro cracking. The delayed Coker is an important residue conversion process. The need for delayes coking is keep pace with the growing demand for transportation fuels and more stringent legislation and the opportunity of improvement in refinery profit margins. Delayed coking is a key technology for residue upgrading or zero fuel oil production.
Advantages of having a delayed Coker unit:-
.Refineries can process heavier, cheaper crudes to increase their refinery margins. . Converts low value residues to high value fuels with moderate capital investment. Cracked products can be processed further in other catalyst units for upgradation, which can’t take the residue as a feed due to their limitation (catalyst poisoning due to metals). Pre-heated feed enters fractionators bottom, mixes with recycle and is fed to the cocker heaters where it is heated to coking temperatures. It is then transferred to coke drums where the trapped liquid is converted to vapor and coke drum overhead vapor is routed to the fractionators, where separation on basis of boiling point difference is done .LCGO and HCGO steams are withdrawn from the fractionator, after respectively. The second stream is routed to naphtha splitter for separation of stabilized naphtha into overhead product. Product from heavy naphtha stripper is sent to the naphtha hydrotreater unit and light is sent to DHDT.The coke deposited in the drum is removed by the application of high pressure water jet and coke and water is discharged from the drum via a chute to a large coke pit. Water is removed from it and reused. Dewatered coke is then taken into loading side via conveyors after crossing the large particles to smaller sizes for better coke handling.
3.3 ALKYLATION UNIT:
Design capacity: 650 KTPA Licensor: Exon mobile research and engineering company, USA. Unit Objective: The unit designed for maximization of MS production as well as to improve its quality in line with premium Euro-IV grade. Feed source: .C4 steam from propylene recovery unit . LPG from AVU and CCR unit . Isobutane from Butamer Unit Product Destination: . Alkylate product is sent to alkylate storage tank. . n-butane is sent to Butamer unit for isomerization to isobutene
PROCESS DESCRIPTION: This sulphuric acid alkylation unit is first of its kind among all refineries of IOCL. This unit is primarily to maximize the production of Alkylate, having high RON, low RVP and low benzene (<0.1 wt %) for blending in MS to improve quantity of motor spirit in line with premium Euro-IV grade. In Alkylation unit, Olefin and Isobutane are mixed with sulphuric acid catalyst in the reactor and chemically combine to form isooctane rich alkylate and it is designed to operate near the lower end the temperature range (2-5.7) degree Celsius in order to maximize alkylate yield and Octane. The unit is designed for butylene’s feed from PRU for two feed cases representing Butamer SOR and EOR operations.
3.4 BUTAMER UNIT:
Design Capacity: 37.389 TPH of normal butane end 35.453 of normal butane feed start of run Licensor: UOPLLC, USA Unit Objective: Butamer unit is aimed to produce iso-butene from n-butane to balance the requirement of isobutene within the Alkylation unit. Feed source: . N-butane from alkylation unit Product destination: . Isobutene product is routed to alkylation unit Catalyst: .Methanator reactor . Isomerization reactor
PROCESS DESCRIPTION: In the drier circuits, both the feed and make up gas driers are designed to operate at least 24 hours each before regeneration operation. The lead generator must be regenerated once its effluent indicates more than 1 ppm water. Drier regeneration operation is fully in auto control. This unit is designed for a smaller catalyst inventory; thus, catalyst capital requirement is reduced. Reactor system is designed in such a way that, during short period of time the reactor is out of service, the second reactor is capable of maintaining continuous operation at design throughput, yield and conversion. If the unit performance drops off and H2S is detected in the stabilizer off gas in excess of 3 ppm, then Hot Hydrogen stripping needs to be started in the reactor circuit. This operation is to be initiated manually using regenerant super heater in service. Unit will be under shutdown during this operation.
3.5 SARU UNIT:
Design Capacity: 185 TPD Licensor: MECS Unit Objective: Sulphuric Acid act as catalyst in alkylation reaction and hence used in alkylation unit. During the reaction, acid soluble polymers reduce equilibrium concentration of the acid required further reaction to occur. So fresh sulphuric acid is continuously added as make up consequently, a purge a stream is continuously withdrawn from the system called as spent acid. This spent acid is regenerated in SARU for production of sulphuric acid. ->Feed Source: . Feed to unit is spent acid from alkylation unit. ->Product Destination: .99.2% sulphuric acid is sent to alkylation unit. Catalyst type\Quantity: . Vanadium catalyst (XLP-220) . Vanadium catalyst (XLP-110) . Cesium promoted catalyst (SCX-2000)
PROCESS DESCRIPTION: The spent acid re generation plant, single train and double absorption is designed by MECS (Monsanto Enviro-Chem System) to produce sulphuric acid @ 185 MTPD of 100% strength as 99.2% minimum strength product. It is produced from spent sulphuric acid generated in alkylation unit. The plant will process spent acid (from alkylation unit), H2S gas (from refinery off gas), and (from FGD UNIT). Sulphuric acid acts as a catalyst in alkylation unit. During the reaction, acid soluble polymers are dissolved in sulphuric acid. Built up of these polymers reduce equilibrium concentration of the acid required for reaction to occur. So fresh H2SO4 , is used as make up in the alkylation unit. The plant designed to regenerate the sulphuric acid from the spent acid, and the balance make-up of the capacity is from hydrogen sulphide generated from the refinery off gases. The of rich- SO2 gas produces sulphuric acid to make up for production requirements above the spent alkylation acid supply of 196 MTPD (90% basis) or 176.4 MTPD (100% BASIS). The sulphuric acid in the feed stream is decomposed in presence of O2 to SO2 purified in gas cleaning section, converted to SO3 and absorbed in water to from sulphuric acid, which is returned to the storage tank in alkylation unit.
