IOCL, Haldia

Indian Oil Corporation Limited, Haldia Refinery

Vocational Training

Sandeep Kumar 09210011 Department of Chemical Engineering Indian Institute of Technology Roorkee

Contents

1. PLANT LAYOUT

2. FUEL OIL BLOCK

3. LUBE OIL BLOCK 4. DHDS(Diesel hydro de-sulfurisation) BLOCK 5. REFERENCES

Plant Layout
Block Flow Diagram of Haldia Refinery
Fuel Gas LPG SR Naph C5 90C

ATU

SRU

Desulphurised Fuel Gas Sulphur LPG Naphtha MS( 3 GRADES)

90 140C

CRU HGU KHDS

H2

Crude

C D U 1

C D U 2

Kero Cut St.Run G.O JBO

MTO RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

DHDS

FCCU
GO SO RCO

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Crude Distillation Unit (CDU)

Feed: Arab mix (lube bearing) and Dubai (non-lube bearing) Crude oil. Process : Separation of liquid feed mixture (crude oil) into different components on the basis of relative volatility. Products : Short Name Gas LPG NAP KERO ATF LGO HGO RCO Full Name Fuel gas Liquefied Petroleum Gas Naptha Kerosene Aviation turbine fuel Light gas oil Heavy gas oil Reduced crude oil Cut Range oC C1-C2 C3-C4 C5-140 140-270 140-240 240/270-320 270-370 >400 Usage Internal Fuel Domestic fuel gas MS Component Domestic Fuel Aero planes HSD component Jute industry VDU feed

Operating parameters
Whole process can be divided into five major operations:

1.

Desalting: (To remove Calcium and Magnesium salts) Temperature : 120 C -130 C Pressure : 7.5-8.5 kg/cm2 Water injection : 4-6% of feed

2.

Prefractionator: Inlet Temperature : 180 C -200 C Top Temperature : 115 C -120 C Top Pressure : 2.6-3.2 kg/cm2 Stripping Steam : 2500-3000 kg/hr Flash Zone Pressure : 2.7-3.4 kg/cm2
Crude Heater: Coil Inlet Temperature : 270 C Coil Outlet Temperature : 350-370C Radiation Skin Temp : 440 C

4.

Operating parameters
3. Atmospheric Column: Column Top Temperature Column Bottom Temperature Column Top Pressure Stripping Steam Flash Zone Temperature Flash Zone Pressure 4. Stabilizer: Feed Temperature Top Temperature Bottom Temperature Top Pressure : : : : 105 C 72 C 177 C 10.5 kg/cm2 : 115C -135C : 360C : 1.7-1.9 kg/cm2 : 2500-3000 kg/hr : 354C : 2.0 kg/cm2

Too low coil outlet temp

CONDENSER Reduce crude viscosity Top section Temp: 112-130 oC decreases. Flow rate : 23 m3/hr Unsatisfactory fractionation REFLUX 29
B22

LPG
Reflux Drum

between JBO and RCO.

B22

19

TOP CR

Stabilization and splitting Heavy Naptha

Too high Coil outlet temp

Too low Top temp Too high Top temp

Cracking may result KERO DRAW Reduced crude not as 12-18 KERO CR specification for vaccum/FCCU Kerosene flash point becomes feed. LGO DRAW low HSD condensation may occur Water CR Vapor
B22

VS
KERO R/D VS LGO R/D

B22

12 Desalted crude oil 7 6

HGO Draw

VS
HGO R/D

T=265oC

JBO Overhead product end point Overflash Temp = 350-360 oCVS (Superheated steam) point becomes more and out of RCO specification. High Kerosene flash point.

CRUDE DISTILLATION UNIT

 The draw off temperature, end HSD point, viscosity of Gap between overhead HSD and JBO Top CR Withdrawal C Too high Temp: 145/110 increases. LPG and KeroseneDrum decreases. REFLUX Flow rate : 130 Reflux increases m /hrKero CR off should decrease. So, JBO draw 29
CONDENSER
B22

B22

19

Stabilization and Crude Preheats increases.

TOP CR

HSD withdrawal decreases Kero CR

Too high CR
Desalted crude oil

The draw off temperature, as well KERO DRAW as end point of HSD decreses. 12-18 KERO CR Fractionation between HSD and JBO decreases. LGO Overhead reflux decreases. DRAW Temp: 204/149 oC Crude desalter temperature HSD CR Vapor Flow rate : 330 m3/hr increases. HGO Draw 12 Overhead condenser duty 7 decreases.
B22

JFGOPF splitting BH Heavy HSD DRAW Naptha Temp: 283 oC VS Flow rate : 70 m3/hr Steam : 500 kg/hr R/D KERO
VS LGO R/D

B22

T=265oC

VS

JBO Overflash HGO R/D VS (Superheated steam) RCO

CRUDE DISTILLATION UNIT

Top section Gauge Pressure: 1.7-1.9 kg/cm2

CONDENSER
B22

29
B22

REFLUX

LPG
Reflux Drum

19

TOP CR
B22

Stabilization and splitting

KERO DRAW

Heavy Naptha

KERO CR

12-18

VS
LGO DRAW

KERO R/D VS LGO R/D

B22

HSD CR 12 Desalted crude oil 7 6

Vapor HGO Draw

VS
JBO Overflash HGO R/D VS (Superheated steam) RCO

T=265oC

CRUDE DISTILLATION UNIT

OHCU AT HALDIA REFINERY

1. Feedstocks: It is blend of Intermediate oil : 34% Light oil : 31% Heavy oil : 4% Deasphalted oil (DAO) : 9% Spindle oil : 22%

The unit is based on 65-75% conversion and un-converted oil will serve as a FCCU feedstock. Main aim of maximizing diesel, recovering LPG while minimizing Naptha, Kerosene and fuel gas. The unit has an objective for the 1.85 MM metric ton/year (249.5 m3/hr i.e. 112% of design) It is licensed by CPCL from Chevron Lummus Global LLC (CLG).

Process chemical reactions

1. Hydrotreating: It consists different reactions.

Hydrodesulfurization: Remove sulfur from feed. Hydrodenitrification: Remove Nitrogen from feed. Hydrogenation of oxygenated compounds: Remove oxygen from feed. Metal Removal: Metallic contaminants are removed by apparent decomposition of compounds with the metal being retained on the catalyst, by either adsorption or chemical reaction. Hydrogenation of aromatics and olefins: Olefins are intermediate products in bifunctional mechanism of cracking and Isomerization.

Process chemical reactions

2.Hydrocracking: The major reaction occurring in hydrocracking reactor are.
Hydroisomerization and then cracking into lighter isoparaffins. Monocyclic napthenes are dealkylated and then isomerized into light isoparaffins and lower molecular weight napthenes. Bicyclic napthenes are reacting open one ring in order to form alkyl substituted monocyclic napthenes. Alkylbenzenes are dealkylated to form aromatics and isoparaffins. Benzonapthenes reacts primarily by opening of naphthenes rings to producd alkylbenzenes. Polyaromatics first undergo hydrogenation of one ring to form benzonapthenes.

Process chemical reactions

3.Coking:
The heavy aromatics (asphaltenes) are not crack able compounds and are

strongly adsorbed on the acidic sites of catalyst where they subsequently polymerize and eventually form coke.

The phenomena is favored at high temperature and low Hydrogen Pressure.

Catalysts
1.Hydrotreating catalyst:
HR 360. The metals Ni and MO need to be in their sulfied form to work in an H2S atmosphere and to be very stable under design operating conditions. Support is an alumina base.

The Catalyst is supported by 3 guard beds in first reactor.

First bed to trap particles and iron sulfide.

Second and third to trap the metals.

2.Hydrocracking catalyst:
A bifunctional catalyst. Control amount of zeolite in its support and Ni/Mo metals in their sulfied form HYC 652.

Feed

3 Guard Beds

Partial Pressure

LHSV In Hydrotreater and Limits Coke deposits S Hydrocracker both : 1.7/h

Hydrogen S

EOR Outlet Temp: 434.8 oC EOR Outlet Temp: 410.4 C

Limits T rise in each bed by o quenching. SOR Inlet Temp: 383.5 oC SOR Inlet Temp: 379.8 C o SORdisperses liquid oC SOR Outlet Temp: 390.1 C Outlet Temp: 405 Hydrocarbon It o EOR Inlet Temp: 413.5 oC EOR Inlet Temp: 399.7 C through catalyst bed. Recycle Hydrogen o

Space Velocity HR 360

Increase in Temperature

Hydrocogen partial Pressure Hydrotreater Inlet Pressure: 171 kg/cm2 Hydrotreater Outlet Pressure: 165 kg/cm2 Hydrocracker Inlet Pressure: 165 kg/cm2 HydrotreaterReactor Pressure: 161 kg/cm2Reactor Outlet Hydrocracking Hydrotreating

Increase Catalyst activity AIR Cooler A Coke deposit increases. HYC 652

Having same effect as increase in Temperature If T increase is limited then lowering space velocity give catalyst activity. HP Separator
PRT MP Separator TO SWS

Fractionator

Washing water

Important Properties of LOBS

1. Kinematic Viscosity (KV) 2. Viscosity Index (VI) 3. Pour Point 3.Flash Point

4. Color
5 .Oxidation Stability
LOBS (As per API) GROUP 1 GROUP 2 GROUP 3 VI 80-120 80-120 >120 SULPHER % >0.03 <0.03 <0.03 SATURATES % <90 >90 >90

Lube Oil Block (LOB)

Vacuum Distillation Unit (VDU)

FEED: RCO(Reduced Crude Oil) from bottom of Crude Distillation Unit. PROCESS: Vacuum distillation, because boiling point reduces with decrease in pressure.

Operating conditions for Furnace :

Feed inlet temperature Feed outlet temperature : 286 : 400 OC
OC

Ejectors
GAS OIL

Vacuum column : Flash zone pressure : 100-125 mm Hg. Flash zone temperature : 380 OC Top pressure : 60-80 mm Hg. Top temperature : 80 OC Product draw off temperature :232, 245, 333 & 370 for SO, LO, IO &HO Bottom section :4 Trays Middle section : 22 Trays Top section : 3trays (including packing Equivalent 2 tray height.)

SPINDLE OIL

LIGHT OIL REDUCED CRUDE OIL

INTERMEDIATE OIL

MP STEAM

HEAVY OIL

SHORT RESIDUE

VACUUM DISTILLATION UNIT

Lube oil block (LOB)

Block Flow Diagram of Haldia Refinery To recover valuable oil left in the Fuel Gas ATU SRU Vacuum Residue. Around 25-30% oil is left LPG in the VR. The recovered oil is90C called C5 SR Naph DAO, which is very good feed for HVI CRU 90 140C HGU LOBS. Kero Cut
DAO is recovered by extraction. Liquid Crude propane 1 2 JBO oil dissolves the and rejects asphalts.
St.Run G.O GO SO RCO

Desulphurised Fuel Gas Sulphur LPG Naphtha MS( 3 GRADES) MTO RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

C D U

C D U

KHDS

H2

DHDS

FCCU

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Lube oil Block (LOB)

Purpose : To remove aromatic Block Flow Diagram of Haldia Refinery hydrocarbons from vacuum Desulphurised 38 kg/cm2 Fuel Gas distillates and DAO for Fuel Gas Sulphur ATU SRU LPG LPG improving VI of the products. Naphtha
SR Naph C5 90C 90 140C

Pressure :

Temperature: 60-80 oC
C D U 1 C D U 2
Kero Cut St.Run G.O JBO

CRU

KHDS Propane Feed ratio : 6-12 Crude

Separation process is solvent MTO HGU extraction with furfural. RTF/ATF H Kerosene Furfural dissolves aromatics (2 GRADES) DHDS HSD
2

MS( 3 GRADES)

Licensor: Kellog
GO SO RCO

JBO (2 GRADES)

FCCU

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Lube oil Block (LOB)

Block Flow Diagram of Haldia Refinery
Fuel Gas LPG SR Naph C5 90C

Gauge Pressure : 1-2kg/cm2

Desulphurised Temperature: Top 95-130Gas Fuel Sulphur ATU SRU o oC, Bottom 45-80 C LPG Naphtha

90 140C

CRU KHDS

Crude

C D U 1

C D U 2

Kero Cut St.Run G.O JBO

Solvent to Feed ratio : 1.2-2 MTO HGU

DHDS Licensor: IPIP
H2

MS( 3 GRADES)

RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

FCCU
GO SO RCO

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Lube oil Block (LOB)

Block Flow Diagram of Haldia Refinery Purpose: To separate the wax from the Raffinates Fuel Gas ATU SRU LPG obtained from atmospheric C5 90C SR Naph extraction Units (FEU & CRU 90 140C NMPEU) to lower the pour HGU Kero Cut C point of the KHDS products. H D U St.Run G.O Extraction and DHDS 2 JBO crystallization to achieve de-waxing. FCCU
2

Desulphurised Fuel Gas Sulphur LPG Naphtha MS( 3 GRADES) MTO RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

Crude

C D U 1

GO SO RCO

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Lube oil Block (LOB)

Block Flow Diagram of Haldia Refinery

Crude

C D U 1

C D U 2

Solvent: MEK & Toluene Fuel Gas LPG in equal proportions. C5 SR Toluene is 90C solvent & Naph oil CRU 90 140C MEK is anti wax solvent. Kero Cut Crystallization is done by KHDS St.Run G.O chilling using Ammonia as JBO refrigerant. a The Wax is byproduct.
GO SO

ATU

SRU

Desulphurised Fuel Gas Sulphur LPG Naphtha MS( 3 GRADES)

HGU
H2

MTO RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

DHDS

FCCU
CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

RCO

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Lube oil Block (LOB)

Block Flow Diagram of Haldia Refinery
LPG Purpose: To convert the high SR Naph viscosity feed likeC5 90C CRU 90 low VR/Asphalt to140C viscosity Kero Cut C C products like VB Tar/ KHDS D D U U St.Run G.O Crude Furnace oil. 1 It is 2 JBO mild thermal cracking process. Feed stock is partly GO cracked in furnace and then SO V LO / IO HO charged intoVsoaker /drum RCO D D Fuel Gas

ATU

SRU

Desulphurised Fuel Gas Sulphur LPG Naphtha MS( 3 GRADES)

HGU
H2

MTO RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

DHDS

FCCU

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

U 1

U 2

HFU

DAO

PDA
Asp.

CDWU MCW VBU BTU

SR LO MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Lube oil Block (LOB)

Block Flow Diagram of Haldia Refinery
Fuel Gas LPG SR Naph C5 90C

ATU

SRU

Desulphurised Fuel Gas Sulphur LPG Naphtha MS( 3 GRADES)

Gauge Pressure : 10 Kero Cut C C

Crude

90 140C

CRU

kg/cm2
KHDS

HGU
H2

Temperature: 440
St.Run G.O JBO

D U 1

D U 2

MTO RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

oC

DHDS

Residence time: 25-30 min GO

SO RCO

FCCU

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Lube oil Block (LOB)

Purpose : To improve the color stability and Lube stocks. Block Flow Diagram of Haldia Refinery
Fuel Gas LPG SR Naph

90 140C

Process: The process is mild ATU SRU hydrotreating using a catalyst C5 90C in presence of H2 CRU
KHDS

Desulphurised Fuel Gas Sulphur LPG Naphtha MS( 3 GRADES) MTO RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

Crude

C D U 1

C D U 2

Kero Cut St.Run G.O JBO

Produces Group 1 LOBS. H

2

HGU

DHDS

FCCU
GO SO RCO

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Lube oil Block (LOB)

System Pressure : 55-60 Block Flow Diagram of Haldia Refinery
Fuel Gas LPG SR Naph

kg/cm2

ATU
C5 90C

SRU

90 140C

Reactor outlet Temperature: CRU 220-340 oC

HGU
H H2 flow rate: 400-450 kg/h
2

Desulphurised Fuel Gas Sulphur LPG Naphtha MS( 3 GRADES) MTO RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

Crude

C D U 1

C D U 2

Kero Cut St.Run G.O JBO

KHDS

DHDS

FCCU
GO SO RCO

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Lube oil Block (LOB)

Purpose : It Haldia Block Flow Diagram ofproduces Refinery
Fuel Gas LPG SR Naph C5 90C

superior grade group 2 ATU LOBS.

SRU

Desulphurised Fuel Gas Sulphur LPG Naphtha MS( 3 GRADES) MTO RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

90 140C

Crude

C D U 1

C D U 2

Kero Cut St.Run G.O JBO

Conversion of Wax Title HGU component to non waxy KHDS H components.

CRU
2

DHDS

N-paraffins to Iso paraffins FCCU

SO

GO

RCO

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Lube oil Block (LOB)

Block Flow Diagram of Haldia Refinery
Fuel Gas LPG SR Naph

System Pressure : 112.5 ATU kg/cm2

SRU

C5 90C

Desulphurised Fuel Gas Sulphur LPG Naphtha MS( 3 GRADES) MTO RTF/ATF Kerosene HSD (2 GRADES) JBO (2 GRADES)

90 140C

Crude

C D U 1

C D U 2

Kero Cut St.Run G.O JBO

KHDS

CRU Reactor outlet Temperature: HGU 220-340 oC

H2

H2 flow rate: 3500-5500 Nm3/h FCCU

SO

DHDS

GO

RCO

V D U 1
SR

V D U 2

Ext.
FEU NMP SDU
S.Wax

CBFS 70 N GR-II 150 N GR-I / II 500 N GR-I / II 850 N 150 BS GR-I/II

LO / IO / HO DAO

HFU

PDA
Asp.

CDWU MCW VBU BTU

LO

MCW FO (2 GRADES) Bitumen(3GRADES) Bit Eml. IFO

Fluidized Catalytic Cracking Unit

FCC occupies a very important place in a refinery because of its relatively low cost conversions of heavy oils to more valuable products. It is the highest profit making part of any refinery. FEED: Vacuum distillate( LO , HO , IO), de-asphalted oil , slack wax, short residue. PROCESS: Catalytic cracking on a moving bed of catalyst. Fluid Catalytic Cracking Unit consists of the following sections: 1. Reactor Temperature : 370 OC Pressure : 1.4 kg/cm2 Regenerator Section Temperature : 700 OC 2. Flue Gas Section 3. Main Fractionator Section 4. Product Recovery Section

Following reactions occur in Rise and Reactor : Cracking reactions C10H22 ------------> C3H6 + C7H16 C8H16 ------------> C5H10 + C3H6 C10H21 ------------> Ar C5H9 + C5H12 Isomerization reactions n- C4H10 ------------> iso- C4H10 Cyclisation of olefins to naphthenes C7H14 ------------> CH3-C6H11 Transalkylation / Alkyl group transfer C6H4(CH3)2 + C6H6 ------------> 2 C6H5CH3 Dehydrogenation reactions n- C8H18 ------------> C8H16 + H2 Dealkylation Iso C3H7-C6H5 ----------> C6H6 + C3H6

FUEL GAS FLUE GAS TO INCINRATOR

LPG + NAPHTHA

REACTOR RG-2 HEAVY NAPHTHA

AIR FRACTIONATOR LCO TO RISER HCO TO RISER FLUE GAS TO INCINRATOR RG-1 AIR SPENT CATLYST RISERR

FEED + STEAM

SLURRY TO CATALYST RECOVERY

RESIDUAL FLUIDISED CATALYTIC CRACKING UNIT(RFCC)

PRODUCT: Fuel Gas, L.P.G. , Gasoline of High Octane Number , Diesel Component , Fuel Oil Component.