PREPARED BY:

Name College Department

Sayan Jadavpur Chemical
Bhowmik University, Engineering
Kolkata
Koushiki Jadavpur Chemical
Banerjee University, Engineering
Kolkata
Shritama Jadavpur Chemical
Saha University, Engineering
Kolkata
Dipanyita Heritage Chemical
Mondal Institute of Engineering
Technology,
Kolkata
TRAINING REPORT AT Poumi Heritage Chemical
Ghosh Institute of Engineering
I.O.C.L., HALDIA Technology,
Kolkata
REFINERY
Winter Vocational Trainee Report for the
working period from December 21, 2018-
January 4, 2019.
 PREFACE
Vocational Trainings play a vital role in the upliftment of future engineers. It bridges
the gap between the theoretical and practical aspects of engineering. We were
fortunate to undergo an industrial training at Indian Oil Corporation Limited, Haldia
Refinery. The experience gained during this short vocational training was invaluable
to say the least. It was very informative wherein we learned about the various unit
operations and processes concerned with the petroleum refining industry. The field
visits were exciting and educative wherein we learned about the various equipments
and saw them in operation. We were also exposed to a professional environment
where we observed how professionalism affects the smooth functioning of such a big
enterprise and learned about its nuances.

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 CONTENTS
 About IOCL
 Haldia Refinery
 Various blocks at Haldia Refinery:
1. Fuel Oil Block (FOB)
2. Lube Oil Block (LOB)
3. Diesel de-hydro de-sulphurization Block (DHDS)
4. Oil Movement and Storage Block (OM&S)
5. Effluent Treatment Plant (ETP)
6. Once Through Hydro Cracker Unit Block (OHCU)
 Acknowledgement

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 ABOUT IOCL
Indian Refineries Limited was formed in 1958 for refining and manufacturing of
petroleum products, with Shri Feroze Gandhi as its Chairman.
This was followed by the formation of Indian Oil Co. in 1959, for marketing and
distribution of petroleum products.
On 1st September 1964, as a step towards achieving improved efficiency, Indian
Refineries and Indian Oil Co. were merged and Indian Oil Corporation Limited (IOC)
was born.
With 33,000 plus work force, extensive refining, distribution and marketing
infrastructure, and advanced R&D facilities, Indian Oil plays a significant role in
fuelling the socio economic development of the country with a mandate to ensure
India’s energy security and self-sufficiency in refining and marketing of petroleum
products, Indian Oil in the past six decades has provided energy access to millions of
people across the length and breadth of the country through its ever expanding
network of over 47800 customer touch points.
With a turnover of 506428 crores and a net profit of 21346 crores in 2017-18 and
market capitalisation of 171511 crores, Indian Oil is recognised as one of India’s most
valuable companies.
Indian Oil’s core business has been refining, transportation and marketing of
petroleum products. As on 31st March, 2018, the company owns 11 (including two of
its subsidiary) of Indian’s 23 refineries with a combined refining capacity of 80.7
MMTPA, accounting for 33% of domestic refining capacity.
Indian Oil operates a network of 13,400 km of cross country pipelines for transporting
crude oil, refined petroleum products and natural gas, with a cumulative throughput
capacity of 94.79 MMTPA of oil and 9.5 MMSCMD of gas.

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 HALDIA REFINERY
A brief history:
 Foundation stone was laid by Late Prof. Triguna Sen, Honourable Petroleum
Minister on 6th December, 1969.
 Haldia refinery is the fourth in the chain of 10 operating refineries of Indian Oil
Corporation Limited.
 Haldia refinery was commissioned in January, 1975.
 It is one of the two refineries of Indian Oil Group Companies producing Lube
Oil Base Stocks (LOBS).
 Refining capacity was increased from 2.5 to 7.5 MMTPA in phases and last
revamp was done in 2010.
Facilities:
 4 blocks of process plants – FOB, LOB, DHDS, OHCU
 Offsite facilities include: 208 storage tanks, Bitumen Drum Filling, Effluent
Treatment Plant, Product dispatch facilities.
 Captive power plants with boilers, gas turbine, etc.

Petroleum products from this refinery are supplied mainly to eastern India through two
product pipelines as well as through barges, tank wagons and tank trucks. Products
like MS, HSD, FO and Bitumen are exported from this refinery. It is the sole producer
of Jute Batching Oil. Diesel Hydro Desulphurisation (DHDS) Unit was commissioned
in 1999, for production of low sulphur content (0.25% wt) High Speed Diesel (HSD).
Residue Fluidised Catalytic Cracking Unit (RFCCU) was commissioned in 2001 in
order to increase the distillate yield of the refinery as well as to meet the growing
demand of LPG, MS and HSD. Refinery also produces eco-friendly Bitumen emulsion
and microcrystalline wax. A Catalytic Dewaxing Unit (CDU) was installed and
commissioned in the year 2003 for production of high quality Lube Oil Based Stocks
(LOBS) meeting API Gr-II standards of LOBS. The OHCU was commissioned in
2010 to increase the yield of useful products. At present the refinery is producing
Euro-IV grade HSD (sulphur less than 50 ppm) and MS (sulphur less than 50 ppm) for
use in the metro cities like Kolkata.

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 VARIOUS BLOCKS AT THE REFINERY
FUEL OIL BLOCK
Feed: Crude Oil
Units at FOB:
 Crude distillation unit I (CDU I)
 Crude distillation unit II (CDU II)
 Naphtha Hydro-treating Unit (NHDT)
 Catalytic reforming Unit (CRU)
 Kero Hydro-Desulphurisation Unit (KHDS)
Crude Distillation Unit (CDU)
CDU is called the mother unit of any oil refinery. The purpose of this unit is to
separate different fractions of crude by distillation. The present capacity of CDU I is
3.5 MMTPA and that of CDU II is 4.2 MMTPA. The distillation is carried out at
atmospheric pressure. The following are the basic operations in CDU:
1. Fresh crude preheating.
2. Desalting of crude.
3. Desalted crude preheating.
4. Prefractionation.
5. Prefractionated crude preheating.
6. Heating of crude in furnace.
7. Multi component fractionation of crude in main distillation column.
8. Naptha stabilisation.
9. Naptha Redistillation.
10.De ethaniser.
11.Caustic wash of LPG and excess in naptha.
12.De propaniser.
The following products are formed:
1. LPG
2. Naphtha (Heavy naphtha and light naphtha)
3. Kerosene/ATF
4. High Speed Diesel (HSD)
5. Jute Batching Oil (JBO)

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The bottom of the CDU is the Reduced Crude Oil (RCO) which is further sent to VDU
for further production of marketable products.

Naphtha Hydro treating Unit

It accomplishes various reactions to remove Sulphur, organic nitrogen and oxygen and
to saturate olefin from naphtha which are poisons for downstream reformer catalyst.
Sulphur in the form of mercaptans, aliphatic sulphides are converted to H2S. Organic
nitrogen is converted to NH3. C-O bond is broken to form saturated aliphatic or
aromatic compound together with water.

Catalytic Reforming Unit (CRU)

Octane number of fuel is measured in a test engine and is defined by comparison with
mixture of iso octane and heptane that would have the same anti knocking capacity as
the fuel under test. Catalytic reforming is a major conversion process by which low
octane naphtha is converted to high octane motor gasoline blending stock in presence
of platinum based catalyst at high temperature and hydrogen atmosphere.
• Naphthenes are converted into aromatics through Dehydrogenation.
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 • Dehydrocyclisation of paraffins to aromatics.
• Isomerisation of n-paraffins to iso-paraffins.
• Isomerisation of alkyl-naphthenes to naphthenes and dehydrogenation to
aromatics.
Kero Hydro Desulphurization Treater Unit
Feed: SR SKO, SR ATF, SR MTO, Make up to KHDS
Process: The purpose of this unit is to reduce the Sulphur content of Kerosene (SKO),
ATF/RTF and MTO streams (called Kero cut in general) to the specified levels
through hydro-desulphurization with hydrogen in the presence of catalyst. The raw
Kero cut from CDUs is combined with the recycle gas and make up hydrogen (from
CRU) and pre heated with process heat of the reactor effluent and in furnace thereby it
is fed to the reactor where desulphurization reactions occur to lessen Sulphur content.

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 LUBE OIL BLOCK
The major properties of any lube are:

1. Kinematic viscosity: It is resistance to flow of a liquid offered by the individual

layers of the liquid itself. It should be less to allow easy flow of the lube.
2. Viscosity index: It defines the rate of change of kinematic viscosity with
temperature. Since changing of viscosity with temperature is undesirable,
viscosity index should be lowered.
3. Flash Point: It is the highest application temperature at which oil would work
without getting deteriorated. This is an indication of vaporisation loss. The flash
point of lubes must be low so that lubes do not freeze in cold countries.
4. Pour Point: It is the lowest temperature at which oil would maintain its fluidity
that is remain in liquid state. It should also be low.
5. Colour: Lube oil base stock should be watery in appearance. The colour that we
see in most of the marketed lube oils is due to the additives added to them.
Degradation of colour marks the degradation of the lube base.
6. Oxidation stability: Oxidation stability is required so as to reduce any chances
of polymerisation when in contact with oxygen. This happens due to presence of
unsaturates.

Units at LOB:
 Vacuum Distillation Unit
 Propane De-asphalting Unit
 Furfural Extraction Unit
 Hydro Finishing Unit
 Vis-breaking Unit
 Catalytic Iso Dewaxing Unit

Vacuum Distillation Unit

Its main purpose is to distil the Reduced Crude Oil obtained from Atmospheric
Distillation Column, under vacuum for preparing feed of Lube Oil.
 Feed : Reduced Crude Oil (RCO)
 Products: Gas Oil/Diesel
Spindle Oil
Light Oil
Intermediate Oil
Heavy Oil
Vacuum Residue or Short Residue

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Reduced crude is preheated in a series of heat exchangers (pre-heat exchanger train)
by exchanging heat with the high temperature product streams and then passed
through two oil fired furnaces to achieve a temperature of around 400 0 C. This heated
stream is flashed in the vacuum distillation column operating at 70 mm Hg (below
atmospheric pressure).

Products like SO, LO, IO and HO are drawn off from the column as side streams.
Each product is stripped in their respective stripper columns to remove the lighter
components and increase flash points. Vacuum residue is drawn from the bottom of
the column.

As the boiling points reduce with decrease in pressure, RCO need not be raised to a
very high temperature for further distillation. High temperatures lead to coke
formation in pipelines, columns and vessels blocking/clogging them hence restricting
further flow which is undesired.

Propane De-asphalting Unit

The main aim of this unit is to recover the valuable oil left in the Vacuum Residue.
This is called “bottom of the barrel” processing. The recovered oil called De-
Asphalted Oil (DAO) serves as feed for lube oil making.

 Feed : Vacuum Residue

 Products : De-Asphalted Oil
Asphalt

DAO is recovered by means of extraction process with liquid propane as solvent.

Propane dissolves the oil and rejects the asphalt. Counter-current mass transfer takes
place inside the extractor. Propane dissolves the oil part and comes out from top as the
DAO mix while asphalt being heavy is withdrawn from the bottom as asphalt mix.
Propane is recovered from both the DAO mix and Asphalt mix and re-circulated.
Residual Oil Super Critical Extraction (ROSE) technology is used to recover propane
from the DAO mix where the DAO mix is taken to its critical temperature and
pressure conditions.

Furfural Extraction Unit

This unit removes the aromatic hydrocarbons from the Vacuum Distillates (SO, IO,
HO and DAO) for improving the viscosity index of the products.
 Feed : Vacuum distillates
 Products : Raffinates of SO, LO, HO and DAO
Extracts of SO, LO, HO and DAO

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The separation process used is extraction and the solvent used is furfural. Furfural has
high affinity for aromatics and dissolves them, thereby creating two phases- Raffinate
(lean in aromatics) and Extract (rich in aromatics). Solvent is recovered from both the
streams and recirculated back after proper drying.

Hydro-Finishing Unit

This unit aims at improving the colour and colour stability of Lube Base Stocks.
 Feed : De-waxed oils from SDU
 Product : Finished lube

The process is a mild hydro treating one, using a catalyst in presence of hydrogen at
high temperature and pressure. The process removes contaminants like sulphur,
nitrogen and unsaturates.
At high hydrogen partial pressure and in presence of catalyst, Sulphur and Nitrogen in
the feed gets converted to Hydrogen Sulphide and Ammonia respectively. The
unsaturates are saturated to stable products.

The feed mixed with hydrogen and after being heated in a series of pre-heat
exchangers and furnace is fed to the hydro-finishing reactor. The reactor outlet is
cooled and vapours are removed. The remaining liquid is stripped off lighter
components and sent to storage.

This process gives lubes of various grades as the finished products.

Visbreaking Unit
Here the high viscosity feed stock like asphalt are converted to low viscosity products
like tar or furnace oil which can be put to various other uses in the refinery.

 Feed: Vacuum residue, asphalt and other heavy extracts

 Products: Gas oil, gasoline and fuel gas

Vis-breaking is a mild thermal cracking process where long chained hydrocarbon

molecules in heavy feed stocks are broken into small molecules having low viscosity.
The feed stock is heated to a relatively low temperature of 450 0 C in a furnace and
then held in a soaker drum for longer residence time (30 minutes) to achieve the
required conversion. The soaker outlet is fractionated in a column to obtain on-spec
furnace oil or tar.

Catalytic Iso Dewaxing Unit

This unit aims at producing superior grade lubes of group 2 by conversion of wax
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component in raffinate feed to non-waxy components by the process of isomerisation
of n-paraffins to iso-paraffins.

 Feed : Raffinates of SO, LO, IO, HO and DAO

 Product : Dewaxed oils of SO, LO, IO, HO and DAO

The feed is purified in Hydro-treatment reactor at an elevated temperature. The

sweetened feed is stripped off Hydrogen sulphide and ammonia in a stripper with pure
hydrogen gas. Then it is fed to a dewaxing reactor. The liquid part of reactor outlet is
fractionated to remove lighter components for achieving desired specifications. This
unit is better than SDU because of its increased yield and greater superiority of lubes.

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 Diesel Hydro De-Sulphurization Unit
Sections under DHDS block:
1. Diesel Hydro De-Sulphurization (DHDS)
2. Residue Fluid Catalysed Cracking Unit (RFCCU)
3. Motor Spirit Quality Upgradation (MSQU)
4. Amine Recovery Unit (ARU)
5. Nitrogen Unit (N2)
6. Hydrogen Generation Unit (HGU-1)
7. Vacuum Distillation Unit (VDU-II)
8. Sulphur Recovery Unit (SRU’s)
9. Sour Water Stripper (SWS)

DHDS (De-hydro de sulphurisation Unit)

Feed: SR GO, VGO, LCO, CIDW, KERO CUTS etc.
Process: Sulphur and nitrogen is hydrogenated in this unit from Pressure Swing
Adsorber (PSA) section of steam reforming to produce contaminant sour gases for
treatment in later stages with a minimum change in the boiling temperature of the
feed. It also saturates olefins and reduces oxygenates and organomettalics.
Products: Sweet fuel gas, H2S, NH3, Solid sulphur.
RFCCU (Residue Fluid Catalytic Cracking Unit)
Feed: SO, IO, LO, HO, DAO, SR, LS SO, LS LO, LS IO, LS HO, SL WAX,
EXTRACT, UCO, ISD, TO, FO
Process: The unit process a fees stock mix consisting of several vacuum distillates, de-
ashphalted oil, lube oil extracts and short residue, for maximizing yield and middle
distillates through cracking reactions carried out in the presence of circulating catalyst.

Product: H2S GAS, LPG, LCN, HCN, LCO, CLO, COKE, TCO

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VDU-II (Vacuum Distillation Unit)
Feed: RCO
Process: To distil the RCO under vacuum for producing vacuum distillates for
preparing feedstocks for LOBS manufacturing. Vacuum diesel and VR are by
products and residue respectively.
Product: VGO, SO, LO, IO, HO, SR.

ARU (Amine Recovery Unit)

Feed: Rich Amine
Process: Amine is regenerated in this process. It is passed through a stripper column.
The water inside the amine is reboiled in the autostripper method. The steam takes
away the CO2 and the H2S from the rich amine.
Products: Steam, Lean Amine, CO2, H2S.
SWS (Sour Water Stripper)
Feed: Sour water.
Process: Boiler feed water is mixed with the effluents of any secondary treatment units
such that the Ammonium bi-sulphide salts and the NH4Cl salts they do not deposit in
the pipes and the water dissolves these salts out of the system. This is done in SWS or
Sour water Stripper unit. It’s same as of amine regeneration unit having a reboiler
which uses the internal steam to vent off the effluents.

SRU’s (Sulphur Recovery Unit)

Feed: H2S gas
Process: It converts gaseous H2S into solid sulphur. It is burnt in air to change into SO2
and then it is treated with H2S which is converted in catalytic process into solid
sulphur. These two reactions are together known as the Clauss process. The reaction is
done in multiple stages having condensers and converters to take the reaction to
completion. The final unconverted H2S is converted into solid sulphur in presence of
oxygen in super Clauss process. The solid sulphur is stripped from the dissolved H2S
to remove the probability of mist over the stored solid sulphur.
Product: Solid sulphur

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HGU-I (Hydrogen generation unit)
Feed: Naphtha.
Process: Steam reforming followed by the shift reaction of Naphtha is done for
generation of hydrogen. The reformed gas is separated in PSA section for of pure
hydrogen (99.9% purity)
Product: H2 to DHDS, H2 to CDWU, H2 to EX CRU, H2 to FLARE/FUEL GAS.

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 OIL MOVEMENT AND STORAGE
This unit plays an important role in the storage of imported crude brought by tankers.
Refinery storage tanks are used in storage of crude oil and finished petroleum
products. Products from these storage tanks are dispatched for marketing by tankers,
wagon, drums, cylinders etc.

The mode of dispatch depends on the distance to be traversed and on the capacity of
the pump. For the pumping of highly viscous oils, positive displacement type pump
are used whereas in the case of non-viscous oil centrifugal pump are used.

OM&S-TANK CLASSIFICATION
Petroleum products are classified on basis of flash point.
FLASH POINT: Flash point of a liquid is the lowest temperature at which sufficient
vapour is released to form a flame in presence of air and spark.
CLASS FLASH POINT
A <23 ֯ C
B 23 TO 65 ֯ C
C 66 TO 93֯ C

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Tanks: Almost ⅓rd of the refinery area is allocated for different types of tanks. They
are designed according to the needs of the product conservation like in the case of MS,
SRN there must be a provision to reduce the pressure produced due to the vaporization
of these products and hence these are generally stored in floating roof tanks. By design
there are various types:
1. Fixed roof tank
2. Floating roof tank
3. Fixed cum floating roof tank
Although several other design are also made according to the needs tanks are provided
with
a) Manhole on the shell and roof.
b) Product inlet and outlet nozzle.
c) Drains.
d) Staircase and ladder.
e) Mechanical type level gauge.
f) Open vane with wire mesh or Breather valve or vent with flame arrester

Product is taken to this tank though the inlet by different pumps. There are two outlet
one for blending and product conveying and another for drainage. Generally products
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from different units also contain some amount of water with them. This unwanted
water is drained through that outlet. Some other important operation such as blending
is also done by the outlets. In blending different oil are mixed up to meet the
specifications of the final product oils such as Motor Speed Oils (MS), Diesel etc.
Constant circulation of the product of tank is done for better mixing through these
outlets.

FACILITIES IN OM&S: STORAGE

– Crude receiving tanks and pump to CDU-I&II
– Storage bullets for propane
– Storage and dispatch facility of LPG (horton sphere, mounded bullet
– Intermediate storage tanks for following products and pump of:
 Various naphtha and reformate cuts,
 Kerosene cuts from CDU-I/II, RFCCU and OHCU
 Diesel cuts from CDU-I/II, RFCCU, OHCU and VDU-I/II VGO,
 Various lube oil cuts from VDU-I&II
 Reduced crude storage,
 Vacuum residue storage,
 Raffinate and extract from FEU
 DAO and asphalt from PDA
 Slack Wax
– Storage for IFO and pump
– Storage for chemicals (MEK, toluene, ammonia, furfural
Finished product storage and pumps for naphtha, MS (EURO-III&IV), SK, HSD
(EURO-III&IV), lube oils, MCW, FO and bitumen.

• Loading by Rail - Tank-Wagon Gantry

# River Side gantry for White Oil
# Black oil loading gantry

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 # Single Spur for Lube Oil Loading
• Loading by Road :
# Tank -Truck Loading – White Oil
# Bitumen Tank-Truck Loading
# LPG Tank-Truck Loading
• Bitumen Drum Filling
• Bitumen Emulsion Loading
• Loading of Liquid and Solid Sulphur
• Blending Operations
• Pipelines Transfer
• Coastal Transfer - Loading Tankers / Barge
• Effluent Treatment Plant(ETP)
EFFLUENT TREATMENT PRINCIPLES:
Treatment of the effluent from the various unit of the whole chemical plant is given
prodigious importance. The principle aim of ETP of Haldia Refinery is to obtain water
which is recyclable for numerous purposes in the plant and also to make it safe for
discharging in the outside environment. The effluent consisting of effluent of oil and
water is treated via a series of unit operation mainly clarification and continuous
settling. Effective chemicals and biological treatment are also done to render
flocculation, lowering BOD and COD of the water. These treatments have been
described in the upcoming section.
PROCESS DESCRIPTION:
Feed:- OM&S rundowns and evaporates from various gas treatment plants that
contains water and oils. The exchanger backwash waters from various Heat
Exchangers.
The various units under ETP are:-
 Holding Tank: - It holds the incoming feed and works on the principle of
specific gravity separation. It has two sub sections 1) API Separator (old) that
contains wooden scrappers and 2) TPI (Tilted Plate Interceptors). The holding
tanks are drained from middle in a buffer setup that separates the light floating
oil and the heavy sludge from water.

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 Equalization Tank: - It follows the holding tank that has a similar function and
holds the water for distribution into the further process units.
 Flocculator :- The dissolved H2S and Na2S is removed by addition of H2O2
(1.05kg H2O2/kg of H2S) and (4.75 kg H2O2/kg of Na2S). The other chemicals
that are used PAC (Poly Aluminium Chloride) that has a dual function of
raising the light floats and settling the foreign particles, DOPE (De Oily Poly
Electrolyte) and Alum.
 Pre Biotower Section : - 1) pH adjustment tank- Sulphuric Acid, NaOH and
nutrients
 2) Bio Tower Sump- For equal and even pumping of the liquid into the bio
tower without any variation of flux from the pH adjustment tank.
 Bio Tower: - In the bio tower section, the bacteria is fed with nutrients and the
atmospheric dissolved oxygen by the means of sprinklers. The bio tower also
has packings in it to enhance the residence time of the bacterial treatment.
 Aeration Tank: - The aeration tank has two types of bacteria treatment 1) ARB
(Ammonia Reducing Bacteria) and 2) SRB (Sulphur Reducing Bacteria). The
dissolved Oxygen amount is approximately 2 ppm here. The aeration tank is
sometimes also fed with bacteria nutrients. The quantity is TOC (Total Organic
Compound): Nitrogen : Phosphorus =100:5:1. There are two aeration tanks
primary and secondary in the aeration unit.
 Clarifier Tank: - In the clarifier tank, the bacteria sludge is separated from the
treated water and then recycled in the aeration tank.

PRODUCTS: - The final product of ETP contains less than 5 ppm of oil in the
water. It is then reused within the plant in various processes.

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 ONCE THROUGH HYDRO CRACKER UNIT
The OHCU block consist of the following units:
 Once Through Hydro Cracker Unit (OHCU)
 Hydrogen Generation Unit (HGU)
 N2
Once Through Hydro Cracker Unit
Feed: HS Gas Oil, VGO, LO, HO, IO, EXT, DAO, TCO, H2
Process: The unit is designed to treat heavy vacuum gas oil in order to produce Euro-
IV diesel oil, kerosene, naphtha and LPG, OHCU comprises of a fixed bed catalytic
process using a highly active catalyst for hydro treatment of feed and conversion of
low quality heavy vacuum gas oil to lighter, more valuable products.
Hydrocracking reaction section comprises of 2 steps:
 Hydrotreating
 Hydrocracking

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Processes of both sections involve reaction by hydrogen and are called Hydro
processing.
Hydro treating section:
a) Hydro desulphurization: Molecules containing sulphur are converted to
hydrocarbon and H2S. Sulphur is known poison for downstream catalyst.
b) Hydro denitrification: Nitrogen compounds are converted to hydrocarbon and
ammonia. Nitrogen compounds in the feed, if present in excess of those allowed
by the feed specification will not be removed in hydro treating reactor and shall
inhibit the hydro cracking catalyst activity which will reduce unit performance.
c) Hydro generation of the oxygen compounds: The oxygen containing
compounds are converted into hydrocarbons and water.
d) Metal Removal: Metallic contaminants are removed by apparent decomposition
of the compound, with the metal being retained on the catalyst, by either
adsorption or chemical reaction.
e) Hydrogenation of aromatics and olefins: Olefins are not present in straight run
gas oil and are only found in effluents of secondary conversion processes.
Olefins are intermediate products in the bi functional mechanism of cracking
and isomerization. Aromatics hydrogenation is a strong function of operating
pressure and temperature. Aromatics must be hydrogenated before cracking
reaction can take place.

Hydro cracking section:

The major reactions occurring in the hydrocracking reactor are:
a) Hydro isomerization and then cracking into lighter iso paraffins.
b) Monocyclic naphthenes are dealkylated and then isomerised into light iso
paraffins and lower molecular weight naphthenes.
c) Bicyclic naphthenes are opened to one ring in order to form alkyl substituted
monocyclic naphthenes which follow path described in (b).
d) Alkyl benzenes are dealkylated to form aromatics and iso paraffins. They are
also hydrogenated to form monocyclic naphthenes which follow the reaction
described in (b).
e) Benzonaphthenes react primarily by opening of naphthenic rings to produce
alkyl benzenes which react as described in (d). They may also undergo
hydrogenation of the benzene to form bicyclic naphthenes which follow the
reaction path as described in (b).
f) Poly aromatics first undergo hydrogenation of one ring to form
benzanonaphthenes.

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Product: H2S, Gas, LPG, LT Naphtha, HY Naphtha, SKO, HT-HSD, UCO
Hydrogen Generation Unit (HGU)
Feed: Naphtha
Process: Steam reforming followed by shift reaction of naphtha is done for generation
of hydrogen. The reformer gas is separated in Pressure Swing Adsorber (PSA) section
for of pure hydrogen.

ACKNOWLEDGEMENT
This report wouldn’t have been possible without the constant help and guidance of a
few individuals whose support has been vital to the completion of the report.
We extend our sincere thanks to Indian Oil Corporation Limited for giving us this
wonderful opportunity to do winter training.
We wish to express our gratitude to our supervisors, in all the units that we visited,
who has been abundantly helpful and offered invaluable assistance, support and
guidance. Some of the few names are:-
1. Mr. P. Pal (F.O.B.)
2. Mr. C. Sahoo (L.O.B.)
3. Mr. J. Datta (D.H.D.S.)
4. Mr. K. C. Nayek (E.T.P)

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5. Mr. S. Bhattacharya (O.M.&S.)
6. Mr. R.K. Puram (O.H.C.U)
Special thanks to all my group members for sharing the hard work in making this
report.

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