Avu and Dhdsw2003

Submitted by:
Akhilesh Pathak
B.Tech(CH)
(0906451006)
Mathura Refinery, the sixth refinery of Indian Oil
was commissioned in 1982 with a capacity of 6.0

MMTPA to meet the demand of petroleum products
in north western region of the country, which
includes National Capital Region.
Only company placed at 83rd position among
fortune 500 companies.

Mathura Refinery is the first in Asia and third in
the world to receive the coveted ISO-14001

certification for Environment Management System
in 1996. It is also the first in the World to get
OHSMS certification for Safety Management in
1998.
The major secondary processing units provided
were Fluidised Catalytic Cracking Unit (FCCU), Visbreaker Unit (VBU) and Bitumen Blowing Unit (BBU).
The original technology for these units was sourced
from erstwhile USSR, UOP etc.
Soaker drum technology of EIL was implemented in
VBU in the year 1993.
For production of unleaded Gasoline, Continuous
Catalytic Reforming Unit (CCRU) was commissioned in
1998 with technology from Axens, France.
A DHDS licensed from Axens, France was
commissioned in 1999 for production of HSD with low
Sulphur content of 0.25% wt (max).
With the commissioning of Once Through
Hydrocracker Unit (licensed from Chevron, USA) in
July 2000, capacity of Mathura Refinery was increased
to 8.0 MMTPA.
An oil refinery separates the crude oil in to
different fractions and converts them into usable

products .
Maximize Higher value distillates like LPG, , ATF,
Kerosene and Diesel.

Produce cleaner products.
Crude oil is a complex mixture of thousands of
hydrocarbons. (i.e paraffin, Napthenes & Aromatics)

Brownish black in Color and colloidal in nature
Contains small amounts of non hydrocarbon
impurities in the form of organic compounds of

sulphur, oxygen, nitrogen, metals, water and salts.
Hydro Carbons > 95%

S.no.
Element
Percentage(%)
Carbon
83-87
Hydrogen
11-15
Sulphur
0-3
Oxygen
0-2
Nitrogen
0-0.6
Metals
0-0.1
1.
SulphurCompound H2S, Mercaptans, Thiophenes,

s:
Benzothiophenes
2.
Nitrogen
Compounds :
Pyrrole, Pyridine, Quinoline, etc.
3.
Oxygen
Compounds :
Naphthenic Acid,Phenol etc.
4.
Metallic Derivatives:
Derivatives of Organic acids with

metals
Like Ni, Cu, V, Pb, As.
5.
Water and Salt :
Along with water, Soluble inorganic

compounds like Chlorides, Sulphates of
Sodium, Calcium and Magnesium
s.no.
Product
Key Quality parameters
LPG
Evaporation Temperature at 95 %
Volume =2 deg C, Max
Cu Corrosion =not worse than No.1
Motor Spirit
Density =720-775 Kg/M3

Sulphur=150 ppm, Max
Benzene =1 Vol. %, Max
ATF

Flash Point = 38 deg c, Min
Sulphur=0.25 wt %,Max
Smoke Point =20 mm, Min
s.no.
Product
Key Quality parameters
Diesel

Sulphur= 50 ppm
CetaneNumber = 51 Min
Fuel Oil
Sulphur= 4 wt %, Max
Ash = 0.1 wt %, Max
KV@ 50 deg c =125 , Max
(Winter)
=180 , Max (Summer)
Bitumen
Flash Point =175 deg C,Min

Viscosity at 60 Deg C = 2400
(min) CP
Softening Point =45-55 deg C
Physical
Thermal
Catalytic
Distillation
Visbreaking
Hydrotreating
Solvent extraction
Delayed coking
Catalytic reforming
Propane
deasphalting
Flexicoking
Catalytic cracking
Solvent dewaxing
Hydrocracking,
Isomerization
Blending
Catalytic dewaxing
PRIMARY PROCESSING UNITS

SECONDARY PROCESSING UNITS
The purpose of Primary unit is to

separate the crude in to different
fractions by distillation.
Known as mother unit of the refinery,
consist of
CRUDE DISTILLATION UNIT (CDU)
VACUUM DISTILLATION UNIT (VDU)
Commonly referred as Atmospheric and

Vacuum Distillation unit (AVU)
1.The hydrolysis of salts in crude oil at high temperature

produces HCL and corrodes the Column Internals and
overhead system.
2.The sediments in crude oil fouls the heat exchanger,
furnace tubes and erodes the pipelines by abrasive action.
3.Desalting approaches
-To reduce soluble salt content
-To reduce suspended solids.
-To reduce residual water
4.Desalting of crude oil is carried out in a vessel provided
with electrodes under High potential field(15000-18000
Volts)
5.DesalterOperating condition:
-Temperature range :130-140 deg C
-System pressure :12-14 kg/cm2g
6. The desalted crude is Preheated to about 180-200

deg C and fed to Prefractionator column
7. The purpose of prefractionator is to separate the
lighter hydrocarbons at relatively lower temperature
so as to reduce heat energy requirement across
furnace and to reduce the main fractionator overhead
vapour load
8. Prefractinator are typically used in revamps for
energy conservation and unit capacity enhancement
Prefractionator Operating condition
Top Temperature range= 120-130 deg c
Pressure= 1.5-3.0 kg/cm2g
9. The Pre-fractionator column bottom is fed to
Fractionator column after
heating to 360 370 Deg C in Heat Exchanger train &
The main fractionator separates the pre-
topped crude in to different fractions like

Naphtha, Heavy Naphtha, Aviation Turbine
Fuel, Kerosene, Light Gas Oil, Heavy Gas Oil
and Reduced Crude Oil.
Column Operating Condition
Top Temperature Range =120-135 deg C

Pressure=1.0-2.5 Kg/cm2g
1.VDU objective is to recover valuable product from

RCO relatively at lower temperature.
2.Feed preparation unit for FCC/HCU/VBU/BBU
3.The Operating temp. is about 410-420 Deg C
4. Vacuum is created by steam ejectors.
Column Operating Condition:
Top Temperature range : 50-65 deg C
Pressure: 25-60 mm Hg (a)
RCO from CDU is "heavy", and the separation of this
stream into various fractions would normally require

more energy and higher temperatures.
Higher hydrocarbons promotes coking reactions at
more than 380 deg c at atmospheric pressure fouls

the furnace tubes.
To reduce the amount of energy input required, and
to recover the valuable products from RCO without

cracking, it is distilled under vacuum.
The vacuum condition reduces the boiling point of
the RCO and the fractions are separated relatively at

lower temperature led to energy saving and reduces
fouling of the furnace tubes
s.no
VDU Product
Quality
Processing
LVGO
High S, Low Cetane

no.
Hydrotreatment
(DHDS) for
Sulphur and
Cetane No.,
LDO
High S,Heavy
Hydrocarbons
Fluid catalytic
unit /
Hydrocracker unit
HVGO
High S,Heavy
Hydrocarbons
Fluid catalytic
unit /
Hydrocracker unit
Vacuum Slop
Heavy Hydrocarbons ,
Fuel oil Product
Visbreaker unit /
Coker
Vacuum Residue
Residue
Bitumen Blowing
Unit / VBU / Coker
Objective : To meet the Euro III/IV diesel
quality requirement ( 350/50 ppm S and Min. 51

Cetane No.)
Feed : Straight run diesel / FCC diesel
component/ Coker and Visbreaker diesel

components.
Catalyst : Ni-Mo oxides
Chemical reactions: Desulphurisation and
Denitrification
C5H10SH+H2
C6H12+H2S
Aromatic compound + H2 -->
1.Typical Product Yields

S.no Products
.
Wt%
End Users
1.
Off Gas
2.65
Refinery Fuel gas system after

Amine Wash
2.
Wild Naphtha
2.8
To Naphtha Pool after

stabilisation
3.
Diesel
96.1
To Diesel Pool
2. Operating Conditions :
Temperature range : 320-380 C
System Pressure : 100-105 kg/cm2(g)
S.no.
Characteri BS III
stics
BS-IV
1.
CetaneNo. 51
, min
51
2.
Sulphur,
PPM max
350
50
3.
Flash
point
66 deg C
66 deg C

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Submitted by:

Mathura Refinery, the sixth refinery of Indian Oil

was commissioned in 1982 with a capacity of 6.0

fortune 500 companies.

the world to receive the coveted ISO-14001

The major secondary processing units provided

An oil refinery separates the crude oil in to

different fractions and converts them into usable

Kerosene and Diesel.

Crude oil is a complex mixture of thousands of

hydrocarbons. (i.e paraffin, Napthenes & Aromatics)

impurities in the form of organic compounds of

Hydro Carbons > 95%

SulphurCompound H2S, Mercaptans, Thiophenes,

Pyrrole, Pyridine, Quinoline, etc.

Naphthenic Acid,Phenol etc.

Derivatives of Organic acids with

Water and Salt :

Along with water, Soluble inorganic

Key Quality parameters

Density =720-775 Kg/M3

Density =775-84 Kg/M3

Key Quality parameters

Density =820-845 Kg/M3

Flash Point =175 deg C,Min

PRIMARY PROCESSING UNITS

The purpose of Primary unit is to

Commonly referred as Atmospheric and

1.The hydrolysis of salts in crude oil at high temperature

6. The desalted crude is Preheated to about 180-200

The main fractionator separates the pre-

topped crude in to different fractions like

Top Temperature Range =120-135 deg C

1.VDU objective is to recover valuable product from

RCO from CDU is "heavy", and the separation of this

stream into various fractions would normally require

more than 380 deg c at atmospheric pressure fouls

to recover the valuable products from RCO without

the RCO and the fractions are separated relatively at

High S, Low Cetane

Objective : To meet the Euro III/IV diesel

quality requirement ( 350/50 ppm S and Min. 51

component/ Coker and Visbreaker diesel

Aromatic compound + H2 -->

1.Typical Product Yields

Refinery Fuel gas system after

To Naphtha Pool after

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