Kochi Refinery

PFCCU

Licensor: Technip Stone & Webster Inc

 A PEEK INTO THE HISTORY OF CRACKING
Kochi Refinery

1900- Need for Gasoline Motor Fuel; First thermal cracking

process in USA by Standard Oil Company (Batch process: 399 C,
6 KGC2)
1920s- Discovery that carbon accumulated catalyst can be
regenerated.
1936- First Fixed Bed Catalytic Cracking Unit set up in Socony
Vacuum Refinery in New Jersey (Low gasoline yields, low
efficiency)
1940- Standard Oil Development Co developed Fluidized Bed
Catalytic Cracking Unit
 THE 3 WHYS ?
Kochi Refinery

 Why Crack ?
 To produce high values distillates and to improve refinery
margins.

 Why catalytically crack ?

 To have a selectivity and improve product quality.

 Why fluidize ?
 To move the catalyst between reactor and regenerator to
facilitate burning of coke deposited on catalyst so that catalyst
activity is maintained.
 IMPORTANCE OF FCCU IN
REFINING Kochi Refinery

1. Low cost conversion of heavy oils into lighter more valuable

products.
2. Major producer of LPG and Gasoline.
3. Major producer of feedstock for petrochemical plants.
4. Flexible operation: accommodate additional external feeds to
balance refinery operation.
Basic PFCCU Flow Diagram
Kochi Refinery
 GENERAL DETAILS
Kochi Refinery

Design Case 1
Feedstock : HTVGO and external LPG streams from DCU (16.7 T/hr) &

existing FCCU (52 T/hr).

Capacity : 2.2 MMTPA (275 T/hr) with 10% overdesign.

Objective : Maximization of Propylene

Design Case 2
Feedstock : HTVGO

Capacity : 2.2 MMTPA (275 T/hr)

Objective : Minimization of Propylene
 AN INTRO TO DCC
Kochi Refinery

 Severity lies between that of FCCU and Steam-Cracker.

 DCC product pool mainly comprises of Olefins.

 The following are some specialties about DCC:

1. A high Reactor temperature: Provides additional Heat of Reaction.

2. Low partial pressure with rise steam injection at the rate of 25 wt% of fresh feed:
Takes the reaction till conversion to propylene.
3. ZSM-5 Impregnated Catalyst: Selectivity of reaction to produce more of C3-C4.
4. Reactor Bed Cracking: Adequate residence time to complete the reaction.
5. C4/LCN Recycles: To Maximize Propylene.

 In short, the reaction severity of a DCC is much more intense than a conventional
FCC. The gasoline produced in the first section is selectively converted at high yields
to LPG i.e. C3 and C4 olefins in second part of riser and to C3= in the bed.
DCC Technology Features (18-20 %
Propylene) Kochi Refinery
 MATERIAL BALANCE
Kochi Refinery

Design Case 1 Design Case 2

Total In 275 Total In 275

Feed VGO 275 Feed VGO 275

Total Out 275 Total Out 275

Fuel Gas 26 Fuel Gas 20

LPG 113 LPG 91.17
LCN+MCN 39
LCN+MCN 61.03
HCN+LCO 75
HCN+LCO 79.52
Slurry 0
Slurry 1.98
Coke 22 Coke 21
 A QUICK COMPARISON BETWEEN
EX-FCCU & PFCCU Kochi Refinery
Ex-FCCU PFCCU
Licensor UOP (revamped by S&W) Technip

Capacity 1.65 MMTPA 2.2 MMTPA

Riser Reaction Time 1.8 s 2s
Type of Riser Linear Disengagement Mushroom-type
Disengagement Device Device Disengagement Device
Type of Regenerator Ski-Jump Distributor Bath-tub type Distributor
Catalyst Distributor
3rd & 4th Stage Separator Absent Present

Power Recovery Expander Absent Present

Provision for Injection of Visbreaker Naphtha, C4 Stream, LCN, Slurry

other HC streams to Riser Heavy Naphtha Recycle, Slurry Backwash,
Coker Naphtha, Pool Naphtha
Debutanizer Thermosiphon Reboiling Forced Reboiling
 Process Description
Kochi Refinery

PFCC_Overview_RX-FG & MF.xlsx

PFCCU-Overview USGP & PRU.xlsx

 Petro FCC
Reactor / Regenerator
Flue gas for Heat/Catalyst Recovery "91

Main Air Blower

Reactor Vapor to Main Fractionator ,"97 Kochi Refinery
VHP Air
Reactor
Steam
Anti Surge

IF-LZ-001 IF-C-001 I-FV-001

Dome Steam

MP LP
Steam Cond

Mushroom
Distributor wt % of slurry 1

NNF
Four 2" Upper Slurry Injectors
Reactor
SCSV Stripper
Aeration
MP steam Packings

Riser
IF-V-002
half Rings, Main Stripping Steam 2

peFL
dp i
t an Fluffing Steam
at S
nt C
Y-type Catalyst Spe
Distributor Fludization
Air to Spent Cat Distributor, 6 Points Air Two 2" Lower Slurry Injectors
13
mm
TORCH
OIL
wt % of slurry 1

Regenerator
FG IF-H-001 Slurry recycle from MF BTM"4

,Six 4"Feed InjectorsKSC 8.18

13
mm
Air to Middle Ring
Wt% Of Feed 3.5
13
mm
Re g
e ne
r FRESH FEED from Feed PreHeater,"10
Stan ated Ca
dpip t C4 Injectors 2
e
Air to Inner Ring
FL

C4 Bottom Ring 1 C4 Recycle from De-C3 Bottom ,"4

Emergency
steam LCN Recycle from NSU OH ,"4
LCN Bottom Injector 1
MP Steam,"14
 Flue gas section
Kochi Refinery
HP Steam
from
Flue gas from regenerator overhead Slurry Steam
Generators

Steam Drum

BD
Flue Gas

Water
Hot Water

Hot
Steam

Steam
System

Evaporator

IF-LS-001
Super Heater ESP F-LZ-005

IF-LZ-003

Air
TSP
BFW Injection To Disposal
BFW from Slurry Exch

Saturated HP steam

Flue Gas to FGC

ELECTRICITY
Third
Stage M
Separator
IF-V-006
IF-V-003
Critical Flow Nozzle
ORIFICE
CHAMBER

Fourth Stage Separator Catalyst Filter (Electric traced)

IF-V-007

Plant air
Heatin
g/Cool
ing Air
IF-LZ-002

Break
Vessel

To IF-V-008
 MF Over Head Vapours "84

Petro FCCU Main Fractionator F Reflux "6

IF-G-104
8
Rich Oil from Sponge "8
7
IF-E- IF-E-109
108A/B Kochi Refinery
Lean Oil to Sponge Absorber"6
IF-LZ-102
IF-P-109A/B HWB CWS SW
Rx vapor Feed 6

Reactor Main
Fractionator F
Upper Slurry Recycle "4
5 IF-G-103
Regener
ator

To IF-V-206

IF-V-105
Lower Slurry Recycle "4 IF-E- IF-E-113
210A/B

Feed 4 HWB
F From IF-E-
IF-P-104A/B/C
IF-G- 208
FLO To DHDT
003A/B IF-E-
IF-V-104 IF-E- To CR feed
SH MP Steam IF-P-104A/B/C 107
106A/B tank/CPP
IF-LZ-103
CWS
HWB SW
3
F
IF-H-002

IF-G-102A/B
Wash Oil

M
F FLO
2 IF-G-105A/B To IF-V-303 To IF-V-302
IF-E-105 Start Up Torch Oil
to Regenerator

IF-E-306A/B IF-E-
IF-P-102A/B/C
308A/B
1
From IF-V-303 From IF-P-
Feed "97 btm 308A/B/C

Hot HDT VGO

BFW From unit IUS

Cold HDT VGO

Fuel
Saturated HP Steam MP Steam Gas
to IF-LZ-003 IF-E-104A-D Slurry
IF-E-103

IF-LZ-101

IF-E- Product
Flare
IF-E-112 IF-E-102A-D 101A-D IF-G -101A/B/C
HWB
F IF-P-106A/B
Water
IF-P-105A/B
BD Slurry Backwash to IF-V-001
IF-V-101
Feed Surge Drum
TSP injection
To Unit IUS To OWS/CBD
Pre Heated BFW to Flue gas Cooler
 Catalyst loading-unloading loop
Main Air Blower
VHP Air
Steam
Kochi Refinery

Anti Surge
IF-LZ-001 IF-C-001

MP LP
Steam Cond

To IF-V-004A/B/IF-V-005
Air to Spent Cat Distributor, 6 Points

FG IF-H-001

Air to Middle Ring From IF-V-007

IF-LZ-002
Air to Inner Ring Break
Vessel
Air for Spent Catalyst Loading

IF-J-001
MP Steam IF-V-008

CFH
IF-G-002
Plant Air
IF-G-001A/B
Fresh Cat
Hopper
IF-V-005

IF-V-
Fresh Cat 004
004
Sump A/B
IF-LZ- Spent Cat
Hoppers

Spent Cat Unloading

Air

Plant Air
 Kochi Refinery

IF-G-401
F
LPG mix from IFP-301A/B IF-LZ-404
off spec LPG off spec propylene VGO/DHDT LPG Existing
FCC LPG
IF-MX-402
IF-MX-401
IF-LZ-403

Sweet LPG to De-propanizer

N2 LP Flare

Sweet LPG to storage

IF-LZ-402
IF-G-
IF-LZ-401
402A/B

IF-V-401
F F

Caustic makeup To
NNF
(20 wt%) flare
IF-P-402
IF-P-405A/B IF-P-401A/B

IF-V-402
NNF
IF-P-404A/B
Spent Caustic
DM water

IF-P-403A/B IF-P-406A/B
 Kochi Refinery

PP mix (draining)

CWS
IF-E-503A-D DEC3 Vent
Stripper bottoms
To stripper
IF-V-502

Sour Water
42 From IFV-204 (Sour Water)

From IFV-203 (Sour Water)

IF-P-502A/B
From IFV-304 (Sour Water)

From IF-LZ-102 (Sour Water)

From IF-LZ-201/203 (Sour Water)

Sweet From IFP-LZ-102 (Sour Water)
24
LPG Feed From IFV-301 (Sour Water)
from IFP-P-102A/B/C IFP-V-101A/B IFP-V-102A/B
after
caustic
IF-E-502
treatment
23
IF-P-501A/B CWS
H2O H2O
AT-39101
IFP-E-101 H2O

1
IF-V-501 C4 Recycle vapor to Rx
Propaniser
De-

LP condensate
LP steam

IF-E-501A/B/S

IFP-LZ-102

Sour water
C4 Recycle to Rx
IF-E-504
CWS LPG Storage
LPG
From IF-LZ-404
 Kochi Refinery

Vent Recycle to
IFE-204

IFP-V-106

To IFP-V-101A/B & IFP-V-102A/B

PRESSURIZING GAS IFP-E-111A-H
CWS

137 145 IFP-P-102

A/B/C
107 136
Propylene to IFP-E-101 I/L
from 97
dryers Treated Propelene
87
C3 IFP-P-103 A/B/C
Stripper
DA33901
IFP-V-104
C3 Stripper
133
76
67 IFP-V-105 To IFE-204
IIFP-E- Off Spec
IFP-E-107
Propylene
102A/B DA33902
C3 Rectifier
75 CWS
IFP-V-107
15
1 1

IFP-E-103A/B IFP-E-104A/B
HWB
LP Steam
LP
condensate

IFP-E-105 IFP-P-101 A/B/C

CWS

To LPG storage
 Hot Water Belt System
Kochi Refinery

N2
To ATM at
safe location HOT WATER BELT from IFP-E-102A/B
DM Water
DEMIN WATER

IF-E- IF-E- IF-E- IF-E- IF-E- IF-E- IF-E- IF-E-104A/

Cooling Water
IF-P-V-109

310A/B/C 113 106A/B 108A/B/C 304A/B 303A/B/C IF-E-201A-D 203A/B/C IF-E-110A-H

M
B/C/D
NITROGEN

IFP-LZ-101
Secondary Cooling
water to HWB
HWB
Cooler cooler

IFP-P-104A/B/C PRU rectifier

O/H
CW Return condenser
CWS

IFP-E-111A-H

IIFP-E-102A/B

PRU side
Reboilers

IFP-E-103A/B
HWB

PRU stripper
Reboilers
 FEEDSTOCK
SPECIFICATIONS Kochi Refinery

HTVGO
Parameter Value
Sp. Gravity 0.88-0.90
Total Sulfur, ppmw 200 (max)
Total Nitrogen, ppmw 200 (max)
Basic Nitrogen, ppmw 50 (max)
H2 Content, wt% 12.8 (min)
IBP, 0C 332-335
EP, 0C 611-612
Total Metals (Ni/V), ppmw 0.5 (max)
C7 Asphaltenes, ppmw 500 (max)
Conradson Carbon, wt% 0.05 (max)
Pour Point, 0C 36-38
Aromatics, vol% 7.9-12.4
Aniline Point, 0C 97-98

Kinematic Viscosity, cst @100 0C 10.2-10.6

 Kochi Refinery

Existing
  Coker LPG FCCU LPG
Parameter Value Value
Propylene, vol% 18.2 43.8
Total S, ppmw 100 (max) 100 (max)
Mercaptan Sulfur, ppmw 5 (max) 25 (max)
H2S NIL  
Na+, ppmw 1 (max) 1 (max)
Carbon Sulfide, ppmw 45 11
Carbon Disulfide, ppmw 32 30
Free Water, ppmw 100 100
Cu Strip Corrosion 1b (max) 1b (max)
 Kochi Refinery

  Coker Naphtha Pool Naphtha

Parameter Value Value
Sp. Gravity 0.715 0.67-0.69
IBP, 0C 39  
EP, 0C 144  
Total Nitrogen, ppmw 184 (max)  
Basic Nitrogen, ppmw 122 (max)  
Sulfur, wt% 0.73 0.01
P, vol% 41.45 80-83
O, vol% 37.75 0-8
N, vol% 10.84 9.6-13.3
A, vol% 9.96 2.4-3.8
 PRODUCT
SPECIFICATIONS Kochi Refinery

LPG
Parameter Value
Sp. Gravity 0.571
Mercaptan Sulfur, ppmw <15
CS2/COS <30
Total Volatile Sulfur, ppmw 150 (max)
H2S NIL
Free Water NIL
Cu strip corrosion @38 0C Not worse than 1

Vapour Pressure @ 40 0C, 0C 556.5

Residue on evaporation, wt% 0.05 (max)

 Kochi Refinery
FCCU Naphtha
Parameter Value
TBP Cut-points C5-150 C 0

Sp. Gravity 0.732

RVP @ 38 0C, psia 7.1 (max)
RON 92 (min)
MON 82 (min)
Flash Point, 0C minus 37

Cu Strip Corrosion @ 50 0C Class 1

Existent Gum, g/m3 <30
Potential Gum, g/m3 <40
P, vol% 19.4
O, vol% 42.1
N, vol% 4.7
A, vol% 33.8
Benzene, vol% 2.3
H2S NIL
Total Sulfur, ppmw 40 (max)
Metals (Ni+V) NIL
 Light Cycle Oil Kochi Refinery
Parameter Value
Sp. Gravity 0.964
TBP Cut-points, 0C 150-370
Flash Point, 0C 38 (min)
Pour Point, 0C minus 6.1
Cetane Number 20.1
Cetnae Index 21.5
Total Sulfur, wt% 0.025
P, vol% 9.4
O, vol% 6.7
N, vol% 5.5
A, vol% 78.4
Total Metals NIL
Aphaltenes NIL
Water, ppmw <15

Kinematic Viscosity @50 0C, cst 2.42

Aniline Point, 0C 32
 Kochi Refinery

Heavy Cycle Oil

Parameter Value
Sp. Gravity 1.073

Flash Point, 0C 102

Pour Point, 0C 19

Kinematic Viscosity @50 0C,

cst 22.88

Total Poly-Aromatics, wt% 6

Particulates, ppmw 800
 Kochi Refinery

Clarified Oil
Parameter Value
Sp. Gravity 1.118

Flash Point, 0C 135

Kinematic Viscosity @50 0C,
cst 454.5

Total Sulfur, ppmw 1050

Catalyst Fines after filtration 200 (max)

TBP Cut-points, 0C 370+
 Polymer Grade Propylene Kochi Refinery
Parameter Value
Propylene, wt% 99.6 (min)
H2, ppmw 2 (max)
02, ppmw 1 (max)
CO, ppmvol 0.03 (max)
CO2, ppmw 2 (max)
COS, ppmvol 0.02 (max)
Total Sulfur, ppbw 500 (max)
Methanol, ppmw 1 (max)
Isopropanol, ppmw 1 (max)
Water, ppmw 1 (max)
Ammonia, ppmw 2 (max)
H2S, ppbw 500 (max)
Methane, ppmvol 100 (max)
Arsine, ppbvol 30 (max)
Inerts, ppmw 540 (max)
Fluidization
Kochi Refinery
Fluidization (contd…)
Kochi Refinery
Pressure Balance
Kochi Refinery
Pressure Balance (contd…)
Kochi Refinery
Pressure Balance (contd…)
Kochi Refinery
Pressure Balance (contd…)
Kochi Refinery
Pressure Balance (contd…)
Kochi Refinery
Heat Balance
Kochi Refinery
Heat Balance (contd…)
Kochi Refinery
Heat Balance (contd…)
Kochi Refinery
Heat Balance (contd…)
Kochi Refinery
Heat Balance (contd…)
Kochi Refinery
Heat Balance (contd…)
Kochi Refinery
Heat Balance (contd…)
Kochi Refinery
Heat Balance (contd…)
Kochi Refinery
Heat Balance (contd…)
Kochi Refinery
FCC Reactions
Kochi Refinery
 PRINCIPAL REACTIONS IN FCC
Kochi Refinery

Paraffins  Paraffins + Olefins (Cracking)

Olefins  LPG Olefins (Cracking)
Olefins  Naphthenes (Cyclization)
Olefins  Branched Olefins (Isomerization)  Branched Paraffins

(H Transfer)
Olefins  Paraffins (H Transfer)
Olefins  Coke (Cyclization; Condensation Dehydrogenation)
 Kochi Refinery

Naphthenes  Olefins (Cracking)

Naphthenes  Cyclo-olefins (Dehydrogenation)  Aromatics
(Dehydrogenation)
Naphthenes  Naphthenes with different rings (Isomerization)
Aromatics  Unsubstituted aromatics + Olefins (Side-chain

cracking)
Aromatics  Alkylaromatics (Transalkylation)
Aromatics  Polyaromatics (Dehydrogenation condensation) 
FCC Catalyst
Kochi Refinery
FCC Catalyst (contd…)
Kochi Refinery
FCC CATALYST (CONTD…)
Kochi Refinery
FCC Catalyst (contd…)
Kochi Refinery
FCC Catalyst (contd…)
Kochi Refinery
FCC Catalyst (contd…)
Kochi Refinery
R-R Section
Kochi Refinery
Converter Catalyst
Circulation Path Kochi Refinery
Converter Riser Section
Kochi Refinery
Converter Riser Section
(contd…) Kochi Refinery
 Areas of Caution
Kochi Refinery

• R-R system expansion needs continuous monitoring for every 50

oC during heating-up and cooling-down.
• Spring supports needs to be installed properly; needs to be
unlocked prior to heating-up the system.
• Expansion joint bellows needs to be unlocked before heating up
the system.
• Pipe supports not to be in any contact with structures prone to
expansion.
• If clearances are okay; R-R system will take care of expansion.
 Areas of Caution (contd…)
Kochi Refinery

• Refractory to be free of cracks; cracks will lead to localized hot-

spots after commissioning the unit.
• Installation of slide-valves; proper fitting of the valve gate into the
seating to be ensured.
• Sliding/spring supports across the R-R structure will take care of
expansion.
• Platforms and structures should not be connected to R-R, TSS, and
Orifice Chamber.
• Cleaning of large lines (size > 24”) should be done prior to
installation.
 REACTOR PARAMETERS
Kochi Refinery

 Riser residence time: 2s

 Outlet Velocity : 15-20 m/s
 Operating Temp: 560 0C, Press: 0.8 Kg/cm2
 Design Temp: 609 0C, Press: 3.52 Kg/cm2
 MOC: CS with refractory lining (cold wall design)
 REACTOR INTERNALS
Kochi Refinery

 Total no: of Cyclones:15 pairs (MOC: Alloy Steel)

 Disengagement Device: Mushroom type (MOC: Alloy
Steel)
 Mushroom cap Dia: 6.8m
 Mushroom cap height: 2m
 No: of nozzles: 353
 REACTOR STRIPPER
Kochi Refinery

 Stripper Height: 3.21 m

 Stripper Dia: 5.18 m
 Stripper Packing Type: Koch-Glitsch KFBETM packing
supplied by Technip-Axens (MOC: Stainless Steel)
 RISER
Kochi Refinery

 Design Temp: 609 0C, Press: 3.52 Kg/cm2

 MOC: CS with refractory lining (cold wall design)
 Operating Temp: 560 0C, Press: 0.8 Kg/cm2
 Riser residence time: 2s
 Outlet Velocity : 15-20 M/S
 INJECTORS
Kochi Refinery

 Total no: of injectors: 27 injectors (MOC: CS with varying tips)

 Feed: 6 (SWII Proprietary)

 LCN: 2

 Lift LCN: 1

 C4: 2

 Lift C4:1 Ring

 Slurry Backwash: 2

 Riser Slurry Recycle: 2

 Stripper Slurry Recycle: 4

 Steam: 4+4 (SWII Proprietary)

 STEAM RINGS
Kochi Refinery

Main Stripping Steam Ring

 2 half-rings.
 Located 3585mm below stripper tangent line.
 MOC: 1.25 Cr- 0.5 Mo, Pipe Size: 10", Refractory Thickness: 25mm
 Flow: 5.4 T/hr (2 Kg/T of catalyst)

Fluffing Steam Ring

 1.17 T/hr (for proper fluid characteristic, adequate Head build up for maintaining
SCSV DP)
 REGENERATOR
PARAMETERS Kochi Refinery

• Complete Combustion Type (2% excess O2)

• Design Press: 3.52 Kg/cm2
• Design Temp: 760 0C
• Operating Temp: 709 0C, Press: 1.3 Kg/cm2
• MOC: CS with refractory lining (cold wall design)
• Catalyst Regeneration level : 0.05 wt% C
• Regen Elevation: 45.19 m
• Regen Upper Section Dia:15.09 m
• Regen Lower Section Dia: 12.8 m
• Superficial Gas Velocity: 0.6 m/s
 REGENERATOR INTERNALS
Kochi Refinery

 Regenerator Upper Section Dia:15.09 m

 Regenerator Lower Section Dia: 12.8 m

 Total no: of Cyclones:18 pairs (MOC: Stainless Steel)

 No: of air-rings: 3 (MOC: Stainless Steel)

 Pr Drop across the Ring shall be above 0.07 Kg/Cm2 to prevent

catalyst back up to the ring and erosion

 Catalyst Distributor: Bath-tub type (with 2 Wye arms)

 SLIDE VALVES
Kochi Refinery

Spent Catalyst Slide Valve

 SCSV dP: 0.55 Kg/cm2
 Inlet Press: 1.82 Kg/cm2
 Normal CCR: 55T/min

Regenerated Catalyst Slide Valve

 RCSV dP: 0.55 Kg/cm2
 Inlet Press: 1.80 Kg/cm2
 Normal CCR: 55T/min
Feed Injection Technology
Kochi Refinery
FEED NOZZLE
Kochi Refinery
Feed Injection Technology
(contd…) Kochi Refinery
Converter Reactor Section
Kochi Refinery
Riser Termination Device
Kochi Refinery
Converter Stripper Section
Kochi Refinery
Stripper Packing
Kochi Refinery
Stripper Packing-Advantages
Kochi Refinery
DCC Regenerator
Kochi Refinery
Spent Catalyst Distributor
Kochi Refinery
Kochi Refinery
Air/Steam Rings
Kochi Refinery
Air/Steam Rings (contd…)
Kochi Refinery
Torch Oil Injectors
Kochi Refinery
Cyclone Design
Kochi Refinery
Cyclone Flue Gas Flow Path
Kochi Refinery
Cyclone Dipleg Termination
Kochi Refinery
 Things to be noted
Kochi Refinery

• Cyclone dip-leg splash-plates discharge should not point towards

trickle-valves.
• Expansion of cyclone dip-leg should not impinge on any other
equipment.
Catalyst Slide Valves
Kochi Refinery
Catalyst Slide Valves (contd…)
Kochi Refinery
Catalyst Slide Valves (contd…)
Kochi Refinery
Catalyst Slide Valves (contd…)
Kochi Refinery
Direct Fired Air Heater
Kochi Refinery
 DFAH
Kochi Refinery

 Design Press: 3.52 Kg/cm2.

 Design Temp: 760 0C.
 MOC: CS with refractory lining (cold wall design).
 I/L - O/L Temp : 162-649 0C
 Air Flow-rate: 187 T/hr
 FG B/L Press: 2.5-3.5 Kg/cm2
 Ignitor would be retractable type.
 Heat Duty: 24.1 MM Kcal/hr
 Main Air Blower
Kochi Refinery

•Make: Elliot Ebara

•Drive: VHP Steam; 82.5 TPH
•Air: 314 TPH, 2.1 Kg/cm2, 162 oC
•30% Partial Condensation & 70% Back-pressure type
•Shaft-work: 11.78 MW
•Minimum Continuous Speed: 3168 rpm
•Maximum Continuous Speed: 4263 rpm
•Trip Speed: 4689 rpm
•Rated Speed: 4060 rpm
•Maximum Flow: 397 T/hr
Main Air Blower (contd…)
Kochi Refinery
Flue Gas System
Kochi Refinery
Flue Gas Scheme
Kochi Refinery
Tertiary Separation System
Kochi Refinery
 TSS
Kochi Refinery

 Flow-rate: 334.632 T/hr.

 Temp: 709 0C
 Press: 1.1 Kg/cm2
 20 Cyclones in TSS.
 Design Temp: 760 0C, Press: 3.52 Kg/cm2
 Operating temp: 709 0C
 Max dP: 0.14 Kg/cm2
 Fines at I/L: 400-500 mg/m3
 Particle Size at I/L: 0-80 microns
 Fines at O/L: 72-88 mg/M3 (max . 150 mg/m3)
Orifice Chamber
Kochi Refinery
 ORIFICE CHAMBER
Kochi Refinery

 FGCV: Located ahead of PRT in the bypass line.

 I/L Press: 1.02 Kg/cm2
 dP: 0.61 Kg/cm2
 Outlet-Press: 0.07 Kg/cm2
 Valve opening to be in conjunction with PRT I/L valve opening.
 Quick acting butterfly valve type to accommodate wide range of Press
drop.
 Operating Temp: 709 0C
 Max Fines at I/L: 150 mg/m3
 ORIFICE CHAMBER
(CONTD…) Kochi Refinery

• Design Press: 3.52 kg/cm2

• 3 grids present
• Internal Design Temp: 760°C
• Metal Design Temp: 260°C
• MOC: CS body with internal refractory
• Internals MOC Details: 304 HSS
• Diameter: 3.81 m
• Length: 10.27 m (T/T)
 Power Recovery Expander
Kochi Refinery

•Flow-rate: 329 TPH

•Suction pressure: 1.02 Kg/cm2
•Discharge pressure: 0.07 Kg/cm2
•SC Temp: 699 0C
•DC Temp: 569 0C
•Power produced: 10.98 MW
•Expander Efficiency: 75 %
•Particle Size at I/L: 0-20 microns
•Max Fines at I/L: 150 mg/m3
•Made by Dresser-Rand.
PRE (contd…)
Kochi Refinery
 PRE (CONTD…)
Kochi Refinery

Animation - Expander RT C125 - Training.ppsx

 PRE (contd…)
Kochi Refinery

Diffuser
Rotor, Bearing, and
Seal Assembly
Exhaust Case
Intake Casing
Assembly
Flue Gas Cooler
Kochi Refinery
Flue Gas Cooler (contd…)
Kochi Refinery
 FGC PARAMETERS
Kochi Refinery

 Superheater 2, 1 section of coil (MOC: SA213 T22)

 Superheater 1, 3 sections of coils (MOC: SA213 T11)
 Evaporator, 5 sections of coils (MOC: SA210 Gr A1)
 Economizer, 5 sections of coils (MOC: SA210 Gr A1)}
 I/L Press: 0.07 Kg/cm2, Temp: 569 0C
 O/L Temp: 204 0C, Press: 0.04 Kg/cm2
 Total duty: 33.6 MM Kcal/hr
 Vendor: Thermax Ltd
Electrostatic Precipitator
Kochi Refinery
 ESP Parameters
Kochi Refinery

ESP I/L
o Max I/L Fines: 150 mg/m3
 Design Press: 0.14 Kg/cm2
 Design Temp: 427 0C
 I/L Press: 0.04 Kg/cm2
 I/L particle size: 0-20 microns

124
 ESP Parameters (contd…)
Kochi Refinery

ESP O/L
 Flow-rate: 334.632 T/hr
 Temp: 204 0C
 Press: 0.04 Kg/cm2
 Max Fines at O/L: 50 mg/m3
 Max dP: 0.02 Kg/cm2
TYPICAL DRY ESP
Kochi Refinery
Kochi Refinery
ESP ELECTRIC FIELD
Kochi Refinery
CORONA GENERATION
Kochi Refinery
AVALANCHE MULTIPLICATION
OF GAS MOLECULES Kochi Refinery
NEGATIVE GAS IONS FORMED IN
THE INTER ELECTRODE REGION
Kochi Refinery
PARTICLE CHARGING
Kochi Refinery
PARTICLE COLLECTION AT
COLLECTION ELECTRODE Kochi Refinery
GAS FLOW THROUGH A
PLATE PRECIPITATOR Kochi Refinery
ESP Rapping System
Kochi Refinery
 LIST OF ALL FG VALVES
Kochi Refinery

Sno:
VALVE DESCRIPTION Location Make

1 PDV2102 BUTTERFLY (hydraulics) PRE I/L Control valve, 86" IMI Remosa

2 PDV2101 BUTTERFLY (hydraulics) PRE I/L Trip valve, 86" IMI Remosa

3 PDV1605 BUTTERFLY (hydraulics) Orifice chamber I/L, 62" IMI Remosa

4 MOV2255 GOGGLE VALVE ESP O/L, 93" Z&J Technologies

5 MOV2254 GOGGLE VALVE ESP B/P line, 93" Z&J Technologies

6 MOV2253 GOGGLE VALVE ESP I/L, 84" Z&J Technologies

7 MOV2202 BUTTERFLY (hydraulics) FGC B/P Line, 129" IMI Remosa

8 MOV2201 GOGGLE VALVE FGC I/L, 129" Z&J Technologies

9 MOV2102 GOGGLE VALVE PRE O/L, 129" Z&J Technologies

10 MOV2101 DOUBLE CLAPET (hydraulics) PRE I/L , 86" IMI Remosa

11 IF-SP-079 Auto blind MC I/L, 100" IMI Remosa

 Kochi Refinery

BUTTERFLY VALVE
Kochi Refinery
Kochi Refinery
Kochi Refinery
Kochi Refinery
 Kochi Refinery

Double Clappet Valve

Kochi Refinery
Kochi Refinery
Kochi Refinery
Valve Operation Sequence
Kochi Refinery
 Kochi Refinery

Valve Open
First Disc closes

Second Disc N2 Barrier

closes
Goggle Valve
Kochi Refinery
Hydraulic Power Control Unit
(HPCU) Kochi Refinery
HPCU (CONTD…)
Kochi Refinery
 Kochi Refinery

DCC Operation
Dependent Variables
Kochi Refinery
Converter Process Controls
Kochi Refinery
Feed Loop
Kochi Refinery
Reactor Temperature Control
Kochi Refinery
Effect of Reactor Temperature
Kochi Refinery
Reactor Level Control
Kochi Refinery
Reactor Level
Kochi Refinery
Reactor/Regenerator delta P
Control Kochi Refinery
Catalyst Slide Valve Control
Kochi Refinery
Combustion Air
Kochi Refinery
Regenerator Flue Gas
Kochi Refinery
Flue Gas Cooler Controls
Kochi Refinery
Main Fractionator System
Kochi Refinery
Main Fractionator
Kochi Refinery
 MAIN FRACTIONATOR
Kochi Refinery

 top operating pr 0.5 kg/cm2 bottom pr 0.6 kg/cm2

 top operating temp 117 0c bottom 330 0c
 column height 49.5 m
 PA Distributors are V-notch type.
 Design Press: 3.5 Kg/cm2 , Design Temp (Top): 200 0C
 Design Temp (Bottom): 580 0C
 Coke-trap is present at MF bottom.
 Total 3 nos of chimney trays.
 MAIN FRACTIONATOR
Kochi Refinery

 MF dP: 0.13 Kg/cm2

 Structured packing:
 Bed 1- Mellagrid 64
 Bed 2- Mellapak 2X
 Bed 3- Mellapak 125X
 Bed 4- Mellapak 250Y
 Bed 5- Mellapak 250X
 Bed 6- Mellapak 170X
 Bed 7&8- Mellapak 350Y
 PSV (8): SP - 3.5 Kg/cm2
Heat Removal In Main
Fractionator Kochi Refinery
Heat Removal In Main
Fractionator (contd…) Kochi Refinery
Unsaturated Gas Plant
(USGP) Kochi Refinery
 Wet Gas Compressor (WGC)
Kochi Refinery

•Make: BHEL
•40% Partial Condensation & 60% Back-pressure type.
•VHP Steam Requirement: 97.5 T/hr
•S/C Press: 1.1 Kg/cm2 (a).
•D/S pressure: 17 Kg/cm2
•MOC: Casing- Killed Carbon Steel.
•Shaft-work: 14.4 MW
•Maximum allowable rpm: 5329
•Trip rpm: 5862
WGC (contd…)
Kochi Refinery
WGC (contd…)
Kochi Refinery
WGC (contd…)
Kochi Refinery
Stripper
Kochi Refinery
 STRIPPER
Kochi Refinery

 45 four-pass valve trays.

 Design Press: 20.4 Kg/cm2
 Design Temp: 140 0C
 MOC: SA516 Gr. 70 (Killed Carbon Steel), Trays: 410S SS
 Max dP across column: 0.42 Kg/cm2
 PSV (3): SP - 20.4 Kg/cm2
 Tower Dia: 4.9 m
 Tower Height: 48.65 m
Absorbers
Kochi Refinery
 ABSORBER
Kochi Refinery

 31 two-pass valve trays and 2 chimney trays.

 Design Press: 20.5 Kg/cm2

 Design Temp: 71 0C

 MOC: SA516 Gr. 70 (Killed Carbon Steel), Trays: 410S SS

 Max dP across column: 0.275 Kg/cm2

 PSV (2): SP - 20.5 Kg/cm2

 Tower Dia: 3.4 m

 Tower Height: 39.9 m

Debutanizer
Kochi Refinery
 DEBUTANIZER
Kochi Refinery

 44 valve trays.
 Design Press: 14.5 Kg/cm2
 Design Temp: 220 0C
 MOC: SA516 Gr. 70 (Killed Carbon Steel), Trays: 410S SS
 Max dP across column: 0.4 Kg/cm2
 PSV (2): SP - 14.5 Kg/cm2
 Tower Dia: 5.1 m
 Tower Height: 39.15 m
Naphtha Splitter
Kochi Refinery
 NAPHTHA SPLITTER UNIT
Kochi Refinery

 37 two-pass valve trays.

 Design Press: 3.9 Kg/cm2

 Design Temp: 235 0C

 MOC: SA516 Gr. 70 (Killed Carbon Steel), Trays: 410S SS

 Max dP across column: 0.3 Kg/cm2

 S in Top: 10

 S in Middle: 60

 S in Bottom: 112

 PSV (3): SP - 3.9 Kg/cm2

 Tower Dia: 3.2 m

 Tower Height: 29.7 m

LPG Treatment
Kochi Refinery
Depropanizer
Kochi Refinery
 DEPROPANIZER
Kochi Refinery

 42 Valve Trays.
 Design Press: 20.7 Kg/cm2
 Design Temp: 125 0C
 MOC: SA516 Gr. 70 (Killed Carbon Steel), Trays: 410S SS
 Max dP across column: 0.5 Kg/cm2
 PSV (3): SP - 20.7 Kg/cm2
 Top section dia: 4.6 m
 Middle section dia: 5.8 m
 Bottom section dia: 6.1 m
 Height: 38.8 m
Propylene Recovery Unit-
Treatment Section Kochi Refinery
PP Mix Dryers
Kochi Refinery
 PP MIX DRYERS
Kochi Refinery

 Operating Press: 26.8 Kg/cm2

 Operating Temp: 38 0C
 Regeneration Press: 4.9 Kg/cm2
 Regeneration Temp: 290 0C
 Design Temp (Min/Max; Process) : -21/65 0C
 Design Press (Min/Max; Process): 34.8 Kg/cm2
 Design Temp (Min/Max; Regeneration): -21/350 0C
 Design Press (Min/Max; Regeneration): 9.9 Kg/cm2
 Bed : 1 main bed and 1 guard bed
 PP MIX DRYERS
Kochi Refinery

 Cycle Time: 36 hours

 Guard bed : 6 hours

 Bed: 4A Mol Sieve

 Dessicant Life: 3 years

 MOC: SA 516 Gr.70

 I/l conc of H2O: 730 ppm wt

 I/l conc of CH3OH: 20 ppm wt

 o/l conc of H2O: <10ppm wt

 o/l conc of CH3OH: <10 ppm wt

PP Mix RSH-COS Removal
Beds Kochi Refinery
 RSH-COS REMOVAL BEDS
Kochi Refinery

 Operating Press: 26.1 Kg/cm2

 Operating Temp: 38 0C
 Regeneration Press: 4.9 Kg/cm2
 Regeneration Temp: 290 0C
 Design Temp (Min/Max; Process) : -21/65 0C
 Design Press (Min/Max; Process): 34.8 Kg/cm2
 Design Temp (Min/Max; Regeneration): -21/350 0C
 Design Press (Min/Max; Regeneration): 9.9 Kg/cm2
 RSH-COS REMOVAL BEDS
Kochi Refinery

• Cycle Time: 72 hours towards end of life.

• MOC: SA 516 Gr.70
• Bed Material: BASF Selexsorb COS, BASF Selexsorb CD (RSH)
• Adsorbent Life: 3 years
• I/l conc of RSH : <12 ppmw
• I/l conc of CO: <28 ppmw
• O/l conc of RSH : <0.5 ppm v
• O/l conc of CO: <0.1 ppm v
• PSV (2): SP - 34.8 Kg/cm2
C3 Splitter-Stripper and
Rectifier Towers Kochi Refinery
 C3 STRIPPER
Kochi Refinery

 137 MD Trays, 1 Chimney Tray

 MOC: SA 516 Gr.70 (Killed carbon steel), Internals: 410 SS
 Design Press: 25.7 Kg/cm2
 Design Temp: 110 0C
 Allowable dP: 0.685 Kg/cm2
 Tower Dia: 8.5 m
 Tower Height: 71.5 m
 C3 RECTIFIER
Kochi Refinery

 145 MD Trays, 1 Chimney Tray

 Top 10 Pasteurizing tray : Remove mainly ethane (Components lighter than

propylene)

 MOC: SA 516 Gr.70 (Killed carbon steel), Internals: 410 SS

 Design Press: 23.9 Kg/cm2

 Design Temp: 75 0C

 Allowable dP: 0.685 Kg/cm2

 PSV (1) : SP - 20.7 Kg/cm2

 Tower Dia: 8.5 m

 Tower Height: 79 m
Hot-Water Belt System (HWB)
Kochi Refinery
HWB Distribution
Kochi Refinery
 HOT WATER BELT SYSTEM
Kochi Refinery

Heat Recovery: From PFCCU

 IF-E-110 A-D: Main Fractionator Overhead Condenser
 IF-E-108 A/B: Lean Oil/HWB HX
 IF-E-106 A/B: LCO/HWB HX
 IF-E-104 A-D: Slurry Product HX
 IF-E-113: LCO PA HX
 IF-E-201 A-F: WGC Interstage Cooler
 IF-E-203 A-C: WGC Discharge Cooler
 IF-E-303 A/B: Supplemental Lean Oil HX
 IF-E-304 A/B: Naphtha Splitter Cooler
 IF-E-310 A/B: MCN Cooler
HWB Duty Exchange
Kochi Refinery
C3 Splitter Heat Input
Kochi Refinery
C3 Splitter Control
Kochi Refinery
 PFCCU COOLING TOWER
Kochi Refinery

 Total no: of cells: 9 (8 working + 1 spare) ; each cell can be isolated completely for
maintenance
 Capacity per cell: 4,000 m3/hr        
 Unit Cooling water requirement: 32,000 m3/hr
 Cooling water inlet temperature: 45 oC        
 Cooling water outlet temperature: 33 oC
 Heat Load: 384 MMKCal/hr
 Total no: of pumps: 6 (4 working + 2 spare); 1 steam-driven
 Flow-rate: 8000 m3/hr (per pump)            
 Pump discharge pressure: 5.5 Kg/cm2 (g)
 Commissioning Priority
Kochi Refinery

System wise Priority list for commissioning

SL.No Utility / Auxilary system Priority
1 Service water system 1
Plant Air System (6" Plant air system for Catalyst loading system & 2" Header for utility
2 stations) 2
3 MP steam system (Required for Catalyst loading) 3

4 Fresh & Spent catalyst hoppers , Catalyst loading system to Hoppers 4

5 drinking water system 5
6 Cooling water system , Bearing cooling water system 6
7 Instrument Air System 7
8 Fire water System 8
9 CBD System 9
10 LTBD System 10
11 CRWS System 11
12 OWS System 12
13 HP Steam Condensate system(Pure condensate system) 13
14 LP Condensate system (suspect condensate) 14
15 Condensate recovery system 15
 Kochi Refinery

16 BFW system 16
17 VHP steam system 17
18 HP steam system 18
19 LP Steam system 19
20 LP Flare system 20
21 Congealing flare system 21
22 HP flare system 22
23 N2 System 23
24 FG System (HP/LP) 24
25 DM water system 25
26 FLO System 26
27 Fuel Oil system 27
28 HWB System 28
 Kochi Refinery

SL.No Process System Priority

  RX-RG System 1

1 Main Air blower and associated systems and Dicharge lines  

2 Air Pre heater  

Rx/RG System(RX,RG,TSS,Oriface chambor, Stack, Reactor Vapor line & Vent) &
3 associated lines.  

4 Aeration / Fluidization / Purge Air system  

5 E cat Loading system and associated lines  

6 Fresh catalyst Loading system and associated lines  

7 FGC  
  USGP 2

1 Feed System from B/L to till Feed injectors & B/P line to MF  
2 Torch Oil System  
3 FH002 and associated systems  
4 Slurry System(slurry P/R and Prdoucts)  
5 HCO System  
 Kochi Refinery
6 LCO System(LCO P/R and Products)  
7 Lean Oil System  

8 Main Fractionator Overhead System & 3" Start up Naphtha line to IF-V-103  
9 Sour water system  

10 WGC , WGC interstage and associated systems  

11 HP Separator and associated lines & 3" Start Up LPG line to HP Seperator  
12 Stripper and associated systems  
13 Absorber and associated systems  

14 Sponge Absorber and associated systems  

15 Debutanizer and associated systems  

16 Naphtha Splitter and associated systems  

17 Caustic Wash wash system  
18 Depropanizer and associated systems  

19 Slop System (Debuaniser bottom, LCO,LCN,MCN,CBD drum , CLO)  

  PRU 3

1 PP Mix driers/ RSH-COS removal beds system  

2 C-3 Stripper and associated systems  

3 C-3 Rectifier and associated systems & 6" Start up propylene from storage.  

4 Arsine Removal bed and propylene product circuits  

5 Drier Regeneration circuits  
6 Sulpher bed Regeneration circuits  
  Flue gas Energy Recovery Section  
1 PRE,ESP 4
 PFCC MPR & RR PACKAGE
Kochi Refinery

REACTOR
MAIN FRAC
DEPROPANIZER
& DEBUTANIZER

SPENT CAT HOPPERS

REGEN

TSS

86” DOUBLE CLAPPET VALVE

ORIFICE
FG DUCT & RR
Kochi Refinery

FLUE GAS DUCT

 ESP & BY PASS DUCT
Kochi Refinery

ESP

84” & 93” GOGGLE VALVE

129” FLUE GAS BYPASS DUCT

FGC, FLUEGAS DUCT & PRE
Kochi Refinery

FGC

PRE FLUE GAS DUCT STRUCTURE

PRE
 Kochi Refinery

REACTOR DISH WITH CYCLONE

 Kochi Refinery

REGEN DISH WITH CYCLONE

 86” DOUBLE CLAPPET VALVE
ISOLATION BETWEEN ORIFICE & PRE
Kochi Refinery

WO SHUTOFF CLAPPETS
BATH TUB SPENT CAT DISTRIBUTOR

Kochi Refinery
 Kochi Refinery

REGEN AIR RINGS

 Kochi Refinery

REACTOR INTERNAL RISER

WITH MUSHROOM
DISTRIBUTOR
 GOGGLE VALVE WORKING
Kochi Refinery

Sammi-Line-Blind-Goggle-Valve-54-150 - 10Youtube.co
m.mp4
 COMPRESSOR SURGE
Kochi Refinery

pressor surge and prevention - I am a Chemical Engineer Facebook - Copy.

Questions ??? Kochi Refinery