PROJECT REPORT

By
NIKITHA SARIPALLI
NATIONAL INSTITUTE OF TECHNOLOGY, WARANGAL

CERTIFICATE
THIS IS TO CERTIFY THAT NIKITHA SARIPALLI WITH
REGISTRATION NUMBER 851262 OF NATIONAL INSTITUTE OF
TECHNOLOGY, WARANGAL OF CHEMICAL ENGINEERING HAS
UNDERGONE INDUSTRIAL TRAINING AT VISAKH REFINERY,
HINDUSTAN PETROLEUM CORPORATION LIMITED, FROM JUNE
02, 2014 TO JUNE 30, 2014.

DURING THE ABOVE MENTIONED PERIOD, HER CONDUCT WAS

FOUND TO BE ______________________________.

M. J. SATYA RAO

UDIT NANDI

Chief Manager (Training)

Manager (Technical Dept.)

HPCL

HPCL

Visakh Refinery

Visakh Refinery

Visakhapatnam

Visakhapatnam

ACKNOWLEDGEMENT
I have taken efforts in this project. However, it would not have been
possible without the kind support and help of many individuals and HPCL
officials . I would like to extend my sincere thanks to all of them.
I am highly indebted to Mr.Satya Rao(Chief Manager Training) and Mr.
Udit nandi ( Manager- Technical Department- VR) . My sincere thanks to
Mrs N.Richa (MS block) , Mrs K .Shailaja(FCCU ) , Mr Kailash Rathod
(Utilities ), Mr A.V.B.S Srinivas & Mr Sudheer (CDU) and Mr Anshul
Arora (DHDS) for their guidance and constant supervision as well as for

providing necessary information regarding the project & also for their
support in completing the project.
I would like to express my gratitude towards member of HPCL for their
kind co-operation and encouragement which helped me in completion of
this project.
I would like to express my special gratitude and thanks to industry persons
for giving me such attention and time.
My thanks and appreciations also go to my colleague in developing the
project and people who have willingly helped me out with their abilities.

INDEX
Topic

Cover Page
Certificate
Acknowledgement
Abbreviations
Company profile
Technical-PAD activities
Oil storage and movement
Crude oil and petroleum refinery process
Product and its specifications
Production-primary unit-CDU
Secondary unit- FCCU
Treating units- DHDS
MS bock
Power and Utilities

Pg no.

1
2
3
5
6
7
8
9
15
20
25
32
39
53

ABBREVIATIONS

FCCU: Fluid Catalytic Cracking Unit

CDU: Crude Distillation Unit
CPP: Captive Power Plant
ETP: Effluent Treatment Plant
DHDS: Diesel Hydro Desulphurisation Unit
PRU: Propylene Recovery Unit
SRU: Sulphur Recovery Unit
MMTPA: Million Metric Ton Per Annum
ATP: Additional Tankage Project
ADC: Atmospheric Distillation Column
RCO: Reduced Crude Oil
LVGO : Light vacuum gas oil
HVGO : Heavy vacuum gas oil
SR : Short residue
NHT : Naphtha hydro treating
DHDS : Diesel hydro de sulphurisation
FCC NHT : Fluid catalytic cracking naphtha hydro treating
CCR : Continuous catalytic reactor
CNU : Cryogenic nitrogen unit
BCW : Bearing cool water
DM : Demineralised
PP : Power plant

COMPANY PROFILE
Hindustan Petroleum Corporation Limited is a mega public sector undertaking
(PSU) and a second largest integrated Oil Company with Navaratna status. It
operates two major refineries one at Mumbai and other at Visakhapatnam each
and has 20% market shares in refining. Its lube refinery at Mumbai is largest in
the country with 40% of the countrys total lube refinery capacity. HPCL
markets the entire range of petroleum products from the lightest of LPG to
heaviest of Bitumen including 200 grades of lubes and greases.

ABOUT VISAKH
REFINERY
HPCL-VR is commissioned with an installed capacity of 0.675 MMTPA in
1957 with a Crude distillation unit expanded to 1.5 MMTPA with various
modifications. Later capacity was increased with commissioning 2 more units
of 3 MMTPA each to 7.5 MMTPA. Crude processing capacity is revised to 8.33
MMTPA after various modifications like PFDs in CDUs, FCC unit, offsite
facilities for online bending. A maximum refining capacity of 9.24 MMTPA is
achieved in the refinery. This refinery can process both indigenous and
imported crude as raw material.

TECHNICAL- PAD ACTIVITIES

1. Normal products yield and quality monitoring

2. Unit test runs for evaluation/Process limitations
3. Process equipment performance analysis
4. Chemicals injection and corrosion monitoring
5. Catalyst performance monitoring and new catalyst
evaluation
6. Cyclone performance analysis (catalyst loss).
7. Performance evaluation of additives like ZSM, DeSOx , GSR.

The refinery operations are divided into different sections :

1. OM &S
2. PRODUCTION
3. POWER AND UTILITIES.

OIL MOVEMENT AND

STORAGE
The units are :

1. Off shore tanker terminal

OSTT located at outer harbour is used to unload crude oil from the tankers and
transported to refinery by pipelines of approximately 8.5 km.

2. Single point mooring facility

In order to handle large crude tankers up to 300,000 TMT, to meet crude requirements
of existing and future crude processing requirements, SPM facility is commissioned.
This facility is located around 4km from the shore and water depth SPM locations is
35 m.
The crude oil tankers will offload crude parcels via two numbers 24 inch floating hose
string connected to tanker cargo piping manifold and SPM piping system. Crude then
will be routed through two nos 24 inch under buoy hose string connected to the under
buoy piping on the SPM which will be routed to the crude oil storage facility of
Indian strategic petroleum reserve Ltd and refinery via a 4 km long 48 inch submarine
pipeline and 1,3 km long 48 inch onshore pipeline.

3. Storage
There are floating roof tanks and cone roof tanks for storage of lighter and heavier
hydrocarbons. Line blending facilities are provided in addition to blending facilities
at storage tanks.LPG used to be stored in Horton spheres. However with the
commissioning of mounded storage total LPG from the refinery is being stored in
LPG mounded storage.

4. Dispatch
Product movement is done through rail, road, pipelines, tankers. Products are
pumped to terminals located nearby refinery for onward distribution. Tankers are
positioned at western arm of inner harbour.

CRUDE OIL
It is a naturally occurring, toxic, flammable liquid consisting of a complex mixture of
hydrocarbons of various molecular weights, and other organic compounds, that are found in
geologic formations beneath the earths surface.

Another Definition:
Crude oil is a mixture of hydrocarbon molecules, which are organic compounds of carbon
and hydrogen atoms that may include from one to 60 carbon atoms. The refining process
uses chemicals, catalysts, heat, and pressure to separate and combine the basic types of
hydrocarbon molecules naturally found in crude oil into groups of similar molecules. The
refining process also rearranges their structures and bonding patterns into different
hydrocarbon molecules and compounds. Therefore it is the type of hydrocarbon (paraffinic,
naphthenic, or aromatic) rather than its specific chemical compounds that is significant in the
refining process. In the reservoir, it is usually found in association with natural gas, which
being lighter forms a gas cap over the petroleum, and saline water, which being heavier than
most forms of crude oil, generally sinks beneath it.
The main types of hydrocarbons present in crude petroleum are:

Paraffin (CnH2n+2 )

Olefin (CnH2n)

Naphthenes (CnH2n-2)

Aromatic (CnH2n-6)

There are certain amounts of non hydrocarbons that are also present in the crude oil:

Sulphur Compounds

Oxygen Compounds

Nitrogen Compounds

Trace Metals

Salts

Carbon Dioxide

Naphthenic Acid

Major Refinery Products :

1. Gasoline
2. Kerosene
3. Liquefied Petroleum Gas (LPG)
4. Distillate Fuels
5. Residual Fuels
6. Coke and Asphalt
7. Solvents
8. Petrochemicals
9. Lubricants

CHARACTERISTICS OF CRUDE OIL IN VISAKHA

REFINERY
1. Arab mix
Specific gravity at 15/15 Deg C : 0.8726
API gravity at 15 Deg C : 30.8
Pour point, Deg C : -26.0
Kinematic viscosity (cst) at 37.8 Deg C : 10.7
Kinematic viscosity (cst) at 98.8 Deg C : 3.85
Water content % wt : 0.4
Sulphur total % wt : 2.35
Nitrogen total % wt : 0.1
Carbon residue(Conradson ), % wt : 4.95

Ramsbottom carbon % wt : 4.15

Asphaltenes, % wt : 15.35
Ash content % wt : 0.01
Wax content % wt : 2.75
Saponification No , mg KOH/ gm : 58.0
Total acidity, mg KOH/gm : 0.32
Inorganic acidity, mg KOH/gm : nil
Characterisation factor, KUOP : 11.9

Traces Metal, ppm :

Vanadium : 38
Nickel : 11
Iron : 5
Sodium : 9
Copper : 0.1
Chromium : 0.14

2. Mumbai High
Specific gravity at 15/15 Deg C : 0.8282
Density, Kg/litre at 15 Deg C : 0.8278
API gravity at 15 Deg C : 39.35
RVP, Kg/sq.cm at 38 Deg C : 0.34
Pour point, Deg C : +30.0
Kinematic viscosity (cst) at 37.8 Deg C : 3.75
Kinematic viscosity (cst) at 48 Deg C : 3.28
Kinematic viscosity (cst) at 50 Deg C : 2.24
Water content % wt : 0.4
Salt content % wt : 0.0032
Sulphur total % wt : 0.17
Nitrogen total % wt : 0.015
Carbon residue(Conradson ), % wt : 1.2
Asphaltenes, % wt : 0.28
Ash content % wt : 0.01

Wax content % wt : 10.6

Congealing point of wax, Deg C : 58.0
Water and sediments by centrifuge, % vol : 0.2
Total acidity, mg KOH/gm : 0.15
Inorganic acidity, mg KOH/gm : nil
Characterisation factor, KUOP : 11.7

Traces Metal, ppm :

Vanadium : 0.3
Nickel : 1.0
Iron : 0.3

PETROLEUM REFINERY PROCESS

Petroleum refining begins with the distillation, or fractionation, of crude oils into separate
hydrocarbon groups. The resultant products are directly related to the characteristics of the
crude processed. Most distillation products are further converted into more usable products
by changing the size and structure of the hydrocarbon molecules through cracking, reforming,
and other conversion processes. These converted products are then subjected to various
treatment and separation processes such as extraction, hydrotreating, and sweetening to
remove undesirable constituents and improve product quality.
Listed below are 5 categories of general refinery processes and associated operations:

1.Separation processes
a. Atmospheric distillation
b. Vacuum distillation
c. Light ends recovery (gas processing)

2. Petroleum conversion processes

a. Cracking (thermal and catalytic)

b. Reforming
c. Alkylation
d. Polymerization
e. Isomerisation
f. Coking
g. Visbreaking

3. Petroleum treating processes

a. Hydrodesulfurization
b. Hydrotreating
c. Chemical sweetening
d. Acid gas removal
e. Deasphalting

4.Feedstock and product handling

a. Storage
b. Blending
c. Loading
d. Unloading

5.Auxiliary facilities
a. Boilers
b. Waste water treatment
c. Hydrogen production
d. Sulfur recovery plant
e.Cooling towers
f. Blowdown system
g. Compressor engines

PRODUCTS AND THEIR

SPECIFICATIONS
The product range of refinery includes :

1. LIGHT DISTILLATES
Constitutes 22 % on crude basis.

a. PROPYLENE:
Propylene also known as propene is the second most important starting product in
the petrochemical industry after ethylene. It is the raw material for a wide variety of
products. Manufacturers of the plastic polypropylene account for nearly two thirds of
all demand. The propylene produced in VR is mainly used in APCL. The propylene
produced has following specifications:
Purity: 95% by wt.
Total sulfur: 5%
Uses : As a petrochemical feedstock in polymer industry.

b. LPG
LPG is basically a flammable mixture of propane and butane. It has
wide variety of uses ranging from domestic purposes to locomotive fuel.
The LPG produced in VR is mainly used in cooking purposes in houses.
VR produces LPG of following specifications:
C5 and higher Hydrocarbons: 2.5%
Total sulphur: 150 ppm

c. MOTOR SPIRIT:
Motor spirit commonly known as petrol is basically a blended product of
many hydrocarbons. It is mainly used as fuel in low locomotives. The
motor spirit produced in VR has following specifications:
Density: 720-775 kg/m3

Research octane number: 91 min

Total sulfur: 150 ppm
Lead content: 0.005 g/ml
Benzene: 1% by vol

2.

MIDDLE DISTILLATES
Constitute 52 % on crude basis

d. KEROSENE
Kerosene is one of the major combustible liquids which has wide uses in our daily
life. It is mainly used in cooking purposes. VR produces kerosene of following
specifications:
Smoke point: 18 mm
Total sulfur: 0.25% by wt
Flash point: 35 0C
Uses: As domestic cooking fuel

e. DIESEL:
Diesel is also a blended product like motor spirit. It is mainly used in transportation
purposes. It is used as fuel in higher locomotives.
Cetane index: 46 min
Flash point: 35 0C
Kinematic viscosity: 2-5 cSt
Density: 820-845 kg/m3
Total sulphur: 350 ppm
Water: 0.055 by vol
Uses: As transportation fuel and in power generation

f. JUTE BATCHING OIL

Flash point : 100 0 C
Kinematic viscosity : 15 cSt

Uses : In jute industry solvent.

3. HEAVY ENDS
Consists of 18 % crude basis.

g. FUEL OIL
Water : 1% by vol
Asphaltenes : 10% by wt
Kinematic viscosity : 80-370 cSt
Sulphur : 4% by wt
Pour point : 27 0 C
Uses : As industrial fuel.

h. LOW SULPHUR HEAVY STOCK

Water : 1% by vol
Kinematic viscosity : 5-100 cSt
Sulphur : 1.8 % by wt
Pour point : 66 0 C
Flash point : 66 0 C
Uses : As industrial power generation fuel.

i. BITUMEN
Water : 0.2 % by vol
Penetration point : 30
Penetration : 30-40,60-70,80-100.
Softening point : 40-55 0 C
Flash point : 175 0 C
Uses : In road paving.

The specifications of diesel and gasoline to be produced is :

Specifications of Diesel
Sulfur, PPMW Max
Cetane Number, Min
Poly aromatics % Max
Density Kg/M3
Distillation
T 85 Max
T 95 Max

Existing
2500

Bharat Stage II
500

EURO III
350

48
No Spec
820-860

48
No Spec
820-860

51
11
820-845

EURO IV
50 (2005)
10 (2011)
51
11
820-845

350
370

350
360

360
No Spec

360
No Spec

Gasoline Specifications

ppmw sulphur, max.

Present

EURO II

EURO III

EURO IV

1000

500

150

50 (2005)
10 (2011)

%Benzene, max.

3 for
Metros

5.0

1.0

1.0

5 for rest
%Aromatics, max.

42

35

%Olefins, max.

18

18

RON, min.

88

95 premium

95 premium

95 premium

91 regular

91 regular

91 regular

85 premium

85 premium

85 premium

81 regular

81 regular

81 regular

MON, min.

RVP, kpa, max.

60

70

60

60

Lead content, g/l, max.

0.013

0.013

0.013

0.013

%Oxygen, max.

Varies

2.7

2.7

%Ethers containing 5 or
more C atoms

%Distilled at 100 deg C,

min.

40

%Distilled at 150 deg C,

min.

40

15

15

46

46

75

75

PRODUCTION
This includes:
1. CDU
2. FCCU
3. DHDS
4. MSBLOCK

CRUDE DISTILLATION UNIT

(CDU)
It is a primary process unit and consists of CDU I , II, III .

MAJOR EQUIPMENT:
Desalter, Atmospheric column, Atmospheric furnace, Vacuum furnace, Vacuum column,
Preheat exchangers/coolers.

PROCESS:
Crude oil is removed of impurities and salts in desalter. It is then preheated in a
battery of heat exchangers to required temperature from the return streams of
atmospheric and vacuum column and finally in a furnace.
In the atmospheric column, the crude oil is fractionated into 5 streams :
Unstabilized Naphtha, Heavy Naphtha , kerosene, diesel, reduced crude oil.
Unstabilized Naphtha is further processed in Stabilizer where LPG and Naphtha
are separated. Naphtha and diesel are sent to blending pools. ATF & MTO are
produced from kerosene cuts.
Reduced crude oil is sent as feed to vacuum distillation unit. The feed is
preheated in fired heater furnace and the vacuum is achieved with the help of set
ejectors. The different fractions obtained are Vacuum diesel, Low vacuum gas
oil, Heavy vacuum gas oil , Short residue.

SR is sent to bitumen blowing unit or visbreaking unit. Gas oils are sent to FCC
units.

UNIT FLOW PROCESS DESCRIPTION.

1. DESALTING:
Crude oil often contains water, inorganic salts, suspended solids, and water-soluble
trace metals. As a first step in the refining process, to reduce corrosion, plugging, and
fouling of equipment and to prevent poisoning the catalysts in processing units, these
contaminants must be removed by desalting (dehydration).
Here electrical desalting process is applied. The oil phase and aqueous phase is
separated with the help of a strong electric field. Electric Desalting is the application
of high-voltage electrostatic charges to concentrate suspended water globules in the
bottom of the settling tank. Surfactants are added only when the crude has a large
amount of suspended solids.
The crude received from the off-site storage is pumped by Unit charge pumps. Crude
is preheated to desalting temperature of 129-136 deg Celsius in successive heat
exchangers, utilizing relatively low temperature fluids such as heavy naphtha, vacuum
diesel, kerosene product, heavy diesel product respectively.
Stripped water from sour water stripper and DHDS-SRU is used for desalting. On
mixing, the undesirable salts present in the crude get dissolved in the wash water and
hence get separated from the crude.
Brine from the desalter is sent to sour water stripper unit and then transferred to ETU.

2. Separation Processes
The first phase in petroleum refining operations is the
Separation/Fractionation/Distillation of crude oil into its major constituents using 3
petroleum separation processes: atmospheric

distillation, vacuum distillation, and

light ends recovery (gas processing).

3. Fractionation
The separation of crude oil in atmospheric and vacuum distillation towers into groups
of hydrocarbon compounds of differing boiling-point ranges (relative volatility) called
"fractions" or "cuts."

4. Atmospheric Distillation Tower

At the refinery, the desalted crude feedstock is preheated in exchangers using
recovered process heat. The feedstock then flows to a direct-fired crude charge heater
and fed into the vertical distillation column just above the bottom, at pressures slightly
above atmospheric and at temperatures ranging from 650 to 700 F (heating crude oil
above these temperatures may cause undesirable thermal cracking). All but the
heaviest fractions flash into vapour. As the hot vapour rises in the tower, its
temperature is reduced. Heavy fuel oil or asphalt residue is taken from the bottom. At
successively higher points on the tower, the various major products including
lubricating oil, heating oil, kerosene, gasoline, and uncondensed gases (which
condense at lower temperatures) are drawn off. In order to maximize heat recovery
and balance tower loading, different refluxes are circulated.
The fractionating tower, a steel cylinder about 120 feet high, contains horizontal steel
trays for separating and collecting the liquids. At each tray, vapours from below enter
perforations and bubble caps. They permit the vapours to bubble through the liquid on
the tray, causing some condensation at the temperature of that tray. An overflow pipe
drains the condensed liquids from each tray back to the tray below, where the higher
temperature causes re-evaporation. The evaporation, condensing, and scrubbing
operation are repeated many times until the desired degree of product purity is
reached. Then side streams from certain trays are taken off to obtain the desired
fractions. Products ranging from uncondensed fixed gases at the top to heavy fuel oils
at the bottom can be taken continuously from a fractionating tower. Steam is often

used in towers to lower the vapour pressure and create a partial vacuum. The
distillation process separates the major constituents of crude oil into so-called
straight-run products. Sometimes crude oil is "topped" by distilling off only the
lighter fractions, leaving a heavy residue that is often distilled further under high
vacuum.

5. Vacuum Distillation
In order to further distil the residuum or topped crude from the atmospheric tower at
higher temperatures, reduced pressure is required to prevent thermal cracking. The
process takes place in one or more vacuum distillation towers. The principles of
vacuum distillation resemble those of fractional distillation and, except that largerdiameter columns are used to maintain comparable vapour velocities at the reduced
pressures, the equipment is also similar.
Topped crude withdrawn from the bottom of the atmospheric distillation column is
composed of high boiling-point hydrocarbons. When distilled at atmospheric
pressures, the crude oil decomposes and polymerizes and will foul equipment. To
separate topped crude into components, it must be distilled in a vacuum column at a
very low pressure and in a steam atmosphere. In the vacuum distillation unit, topped
crude is heated with a process heater to temperatures ranging from 370 to 425C (700
to 800F). The heated topped crude is flashed into a vacuum distillation column
operating at absolute pressures ranging from 350 to 1400 kilograms per square meter

(kg/m2). In the vacuum column, the topped crude is separated into common boilingpoint fractions by vaporization and condensation.
Stripping steam is normally injected into the bottom of the vacuum distillation column
to assist the separation by lowering the effective partial pressures of the components.
Standard petroleum fractions withdrawn from the vacuum distillation column include
lube distillates, vacuum oil, asphalt stocks, and residual oils. The vacuum in the
vacuum distillation column is usually maintained by the use of steam ejectors but may
be maintained by the use of vacuum pumps.

PLANT CAPACITIES
CDU I
Design capacity : 1.8 MMTPA
Actual feed rates : 300 to 330 m3/hr

CDU II
Design capacity : 3.1MMTPA
Actual feed rates : 500 to 550 m3/hr

CDU III
Design capacity : 3.4 MMTPA
Actual feed rates : 540 to 560 m3/hr

FLUID CATALYTIC CRACKING

UNIT
It is one of the secondary processing unit.

CRACKING
Cracking involves the decomposition of heavier hydrocarbon feedstocks to lighter
hydrocarbon feed stocks.
Cracking can be carried out to any hydrocarbon feedstock but it is usually applied for
vacuum gas oil (VGO).
Cracking can be with or without a catalyst.
When cracking is carried out without a catalyst higher operating temperatures and pressures
are required. This is called as thermal cracking. This was the principle of the old generation
refineries.
Now a days, cracking is usually carried out using a catalyst. The catalyst enabled the
reduction in operating pressure and temperature drastically.

CRACKING CHEMISTRY
1. Long chain paraffins converted to olefins and olefins.
2. Straight chain paraffins converted to branched paraffins.
3. Alkylated aromatics converted to aromatics and paraffins.
4. Ring compounds converted to alkylated aromatics.
5. Dehydrogenation of naphthenes to aromatics and hydrogen.
6. Undesired reaction: Coke formation due to excess cracking.
7. Cracking is an endothermic reaction.
Therefore, in principle cracking generates lighter hydrocarbons constituting paraffins, olefins
and aromatics. In other words, high boiling low octane number feed stocks are converted to
low boiling high octane number products.

CATALYST

Acid treated silica-alumina was used as catalyst . 20 80 mesh size catalysts used for FCCR
and 34 mm pellets used for MBRs. During operation, poisoning occurs with Fe, Ni, Vd and
Cu.

EQUIPMENT
The major equipment are regenerator, reactor, main fractionators, primary absorbers, sponge
absorbers, main air blower, wet gas compressor, De butaniser, stripper.

PROCESS DESCRIPTION
The main process technology consists of two flow sheets namely the cracking coupled with
main distillation column and stabilization of naphtha.
The cracking reaction is mainly converting long chain, high molecular compounds to light
weight products for maximisation of CRN and LPG production by value addition of gas oils.
This process employs a catalyst of silica alumina based zeolite in form of very small
spherical particles which behaves as a fluid when aerated with vapour/air .
Vacuum gas oil from vacuum column is pumped to furnace for achieving the desired
temperature.
Fresh feed is mixed with hot regenerated catalyst and enters the reactor at base of riser where
it gets vaporized at the reactor temperature by the hot catalyst. The gas oil commences to
crack immediately after coming in contact with hot catalyst in riser and continues until the oil
vapours are disengaged from the catalyst in the reactor.
Coke which is generated in the cracking reaction gets deposited on the circulating catalyst in
the reaction zone and the spent catalyst flows from the reactor to regenerator, where coke is

burnt off, by air. The flue gases leaving from the top goes to CO boiler where steam is
generated.
Vapours from reactor are fractionated in fractionation section into recycle gas oil that returns
to reactor and products like light and heavy cycle oil fractions are routed to blending pools,
Clarified oil, unstabilized naphtha undergoes further treatment to satisfy the environmental
norms and the sent to storage and dispatch.

UNIT PROCESS FLOW DESCRIPTION

1. Feed
Heavy gas oils and light gas oils from CDU unit is the feed for FCC unit. Feed enters
the cracking reactor. Old regeneration refineries use moving bed reactors. Now a
days, fluidized catalytic cracking reactors are used. The cracked product from the
reactor enters the main distillation column that produces unstabilized naphtha, light
gas oil, heavy gas oil, slurry and gas. The products are distilled to give light gas,
gasoline and light gas oil. The heavier products may be recycled or sent for further
processing elsewhere.

2. Reactor
The basic principle of FCCR is to enable the fluidization of catalyst particles in the
feed stream at desired pressure and temperature.

Another issue for the FCCR is also to regenerate the catalyst by burning off the coke i
air. Therefore, the reactor unit should have basically two units namely a
reactor(FCCR) and a catalyst regenerator(CR). The FCCR consists essentially of two
important components in a sophisticated arrangement. These are the riser and the
cyclone unit assembled in a reactor vessel. Riser: in a riser(long tube), the feed is
allowed to get in contact with the hot catalyst. The hot catalyst is enabled to rise
through the lift media in the riser. The lift media is usually steam or light hydrocarbon
gas. The riser contact time is about 250 milli seconds. The riser is eventually
connected to cyclone units. The catalyst n the vessel is subjected to stream stripping
in which direct contact with steam is allowed to remove hydrocarbons from catalyst
surface.

3. Catalyst Regenerator(CR)
The spent catalyst is sent to a regenerator, where the coke is burned off in air. This
combustion also serves to heat the catalyst The hot regenerated catalyst is then
returned to the riser. Catalyst temperature raised to620 to 750 0C. Lower catalyst
temperature gives partial combustion to CO and needs post combustion. Higher
catalyst temperature gives complete combustion. Flue goes 600 to 760 oC and to 1 to
1.7 bar. Heat recovery from flue gas for steam generation. The spent catalyst which is
relatively cold enters the regenerator unit. Here, air enters the vessel through a sparger
set up. The catalyst is subsequently burnt in the air. His enables both heating the
catalyst(which is required to carry out the endothermic reaction) and removing the
coke so as to regain the activity of the coke. The catalyst + air after this operation will
enter the cyclone separator unit. Unlike the FCCR, the CR does not have a riser.
Therefore, air enters a dense phase of catalyst and also enables the movement of the
catalyst to a dilute phase of catalyst + air. The cyclone separators separate the flue
gas and catalyst as a fluid operation . The activity regained catalyst is sent to the riser
through a pipe. During this entire operation, the catalyst temperature is increased to
620 750 0C. The flue gas is obtained at 600- 760 0 C and is sent for heat recovery
unit to generate steam.

4. Naphtha stabilization
The naphtha obtained is unstabilized, as it consists of various hydrocarbons. It is
therefore subjected to stabilized by continued processing.
The slurry enters a phase separation unit which separates decant oil and a heavier
product. The heavier product is recycled back to cracking reactor. The unstabilized
naphtha subsequently enters a unsaturates gas plant. In the unsaturates gas plant, the
gas obtained from the main distillation column is sent to a phase separator. The phase
separator separates lighter hydrocarbons from heavier hydrocarbons.
The phase separator is also fed with the unstabilized naphtha. The unstabilized
naphtha from the main column is first fed to a primary absorber to absorb heavier
hydrocarbons in the gas stream emanating from phase separator. The gas leaving the
primary absorber is sent to secondary absorber where light gas oil from main
distillation column is used as a absorbent to further extract any absorbable
hydrocarbons into light gas oil. Eventually, the rich light gas oil enters the main
distillation column. The naphtha generated from the phase separator is sent to
stripping to further consolidate and stabilize naphtha. The stabilized naphtha is further
subjected to distillation in debutanizer and depropanizer units. The debutanizer unit
removes butanes and lower hydrocarbons from the naphtha. The naphtha obtained as
bottom product in the debutanizer is termed as debutanized stable naphtha or gasoline

.The butanes and the other hydrocarbons are sent to a depropanizer unit where butanes
are separated from propanes and other lighter hydrocarbons. Thus, butanes are
obtained as lower product and propanes along with other lighter hydrocarbons are
obtained as the top product in the depropanizer unit.

CATALYTIC CRACKING VS THERMAL CRACKING

Catalytic cracking gives more stable products .
For thermal cracking yield or quality of gasoline.
Catalytic operates serve conditions.

ADVANTAGES OF FCC
Heat is efficiently used.
Temperature is controlled.
Catalyst regeneration also controlled.

PLANT CAPACITIES
FCCU -1:
Unit design capacity = 0.95 MMTPA
Unit actual capacity = 1.2 MMTPA

FCCU-2:
Unit design capacity = 0.97 MMTPA
Unit actual capacity = 0.8 MMTPA

PROUCTS:
Fuel gas, LPG, Naphtha, Light Cycle oil, Heavy Cycle Oil, Clarified Oil, Sour water,
Slop.

Vis breaking unit

It is one of the secondary processing units

EQUIPMENT
Furnace, soaker, main fractionators, compressor, stabiliser, sponge absorber.

Process
Vacuum residue from vacuum column after preheating is heated to desired temperature in
fired heater furnace. Streams coming out of furnace are routed to soaker drum for completing
visbreaking reaction. The soaker effluent streams are routed to fractionators column after
quenching by gas oil generating LPG, naphtha, Gas oil, VisTar.

Plant capacities
Design capacity : 1.0 MMPTA
Feed rate : 110 m3/hr

Bitumen blowing unit

It is one of the secondary processing units

EQUIPMENT
Reactors, heat exchangers, compressors.

Process
Hot vacuum bottoms is cooled to 230 oC in steam generator before entering bitumen
converter where air is blown. Reaction is exothermic and heat is recovered from injecting
steam. Different grades of bitumen are obtained by improving penetration.

Plant capacities
Design capacity : 0.225 MMPTA
Feed rate : 30 m3/hr

DIESEL HYDRO
DESULPHURISATION UNIT
(DHDS):
It is a treating unit.

Objective of DHDS unit is to supply high speed diesel with 20 ppm wwt sulphur content with
a capacity of 2.4 MMTPA. The units is set up to remove sulphur from diesel.
The units in this plant are :
1. DHDS unit
2. Hydrogen unit
3. Sour water stripping unit
4. Sulphur recover unit
5. Utilities and off sites

1. Deisel Hydro De-sulphurisation Unit (DHDS)

MAJOR EQUIPMENT:
Reactor, heater, MGC, RGC, feed filter, stripper, stabilizer, heat exchanger, hot
separator, cold separator, coalescer.

PROCESS:
The sulphur compounds present in the diesel is removed in the presence of hydrogen
and catalyst in the reactor maintained at desired temperature and high pressure. H2S
generated in the process is removed after amine treating in SRU.
It consists of two important process

Pre de-sulphurisation i.e. reduction of sulphur content from 1000 ppm to 10 ppm

And then reduction of sulphur content to less than 0.5 ppm

2. Hydrogen generation unit

MAJOR EQUIPMENT:
Reactor(Desulphurisation), stripper, heater, vaporiser, reactor(H2S adsorption) ,
Reformer, Steam drum, Degassifier, Pressure swing absorption vessels , Purge vessel.

PROCESS:
Hydrogen required for the DHDS process is generated in the hydrogen plant using
naphtha as a feed and fuel for burning. The steam reforming reaction of naphtha is
high temperature reaction.

3. SULPHUR RECOVERY UNIT

PROCESS
Hydrogen sulphide rich gas DHDS is routed to SRU for recovery of sulphur and
reducing the h2s content in the fuel gas.

4. LPG MEROX
MAJOR EQUIPMENT
Extractor, caustic pre-wash, disulphide separator, oxidizer, sand filter, caustic settler.

PROCESS
Traces of H2S and mercaptans present in straight and cracked LPG are removed by
oxidizing then into odourless disulfide.

5. CRN MEROX
MAJOR EQUIPMENT
Reactors, caustic settler, sand filters

PROCESS
Cracked naphtha from FCCU mixed with air and routed to a reactor where MEROX
catalyst impregnated on charcoal be removes the foul smelling mercaptans by
converting them to odourless disulfides.

6. ATF MEROX:
MAJOR EQUIPMENT
Coalescer, reactor, water washer, caustic settler

PROCESS
Kerosene along with air is routed to the merox reactor where mercaptans are
converted to disulfides. Entrained caustic is separated out and moisture, extraneous
matter are removed in filters. This helps in manufacture of ATF.
The feed to this unit is a blend of Straight run and cracked gas oil from storages and
refineries in order to produce low sulphur content diesel oil. This unit consists of four
major sections:

DHDS reaction section

Amine absorption section

Stripping section

Naphtha stabilizing section

DHDS reaction section is a hydro treating process, which mainly consists of two
kinds of reactions:

Refining reaction

Hydrogenation

1. Refining reactions.
a. Desulphurisation
Mercaptans, sulphides, disulphides easily react leading to corresponding saturated
or aromatic compounds sulphur combined into cycle of aromatic structures like
thiophene is more difficult to eliminate. This reactions lead to H2S formation and
H2 consumption.

b. Denitrification.
The Denitrification reaction rate is lower than desulphurisation. It occurs in
heterocyclic compounds having aromatic structure. These leads to NH3 formation
and H2 consumption.

2. Hydrogenation reactions
These reactions affect diolefins , olefins and aromatics are exothermic. Diolefins and
olefins converted to saturated compounds. Hydrogenation rate of aromatics are
limited.

PARAMETERS
1. Temperature
Hydro treatment leads to increase in temperature and eventually lead to increase in
coke deposit which should be controlled. Thus temperature is maintained.
2. Space velocity
Lower the space velocity then higher is the reaction rates. As catalyst quantity is
constant space velocity charged by flow rate.
3. Hydrogen partial pressure.
Increase in this will lead to decrease in coke deposit on catalyst and hydrogenation
reaction is enhanced.
4. Feed quantity
It should be a constant. Severity can be with increase with high feed impurities.
Catalyst can absorb silicon, arsenic, metals etc which will affect compounds activity
of catalyst is drastically reduced.

UNIT PROCESS FLOW DESCRIPTION

1. FEED PREHEATING /

REACTION / SEPERATION SECTIONS

The part of feed to DHDS is directly brought to upstream units whereas the rest is sent
to the surge drums level control. The feed blend is filtered though feed filter package
and sent to feed surge drum. Surge drums generate turbulence in the feed flow so that
the feed flow rate does not affect the centrifugal pumps that pump the feed into the
columns.
The liquid phase feed is pumped with the hydrogen recycle. With this we are able to
ensure an adequate hydrogen partial pressure at the inlet of the reactor train.
Polymerisation inhibitor is injected by antifouling agent pumps in the fresh feed
before the feed pump. The make up gas flow rate to the reaction section is controlled
by means of a compressor spill back. The make up gas joins the recycle gas upstream.

The combined make up and recycle stream is routed to the recycle gas compressor.
The reactor inlet temperature is maintained by controlling the fuel gas/fuel oil to the
heater burner. The stream is then let in the first reactor, which includes catalyst
installed in three beds. Cold quenches of hydrogen coming from recycle compressor
are added at the inlet of each new bed. The reactor effluent is split in to two (to
maximize the heat recovery), then mixed together before it enters the effluent
exchanger. To avoid ammonium salt deposits and risk of corrosion, water is injected
at the inlet of effluent gas air condenser by washing water pumps. The sour water
containing ammonium salts is partly recycled to the washing water drum under level
control of cold separator boot.
Only some part of the gas phase from the cold separator goes to the high pressure(HP)
amine absorber. From here, H2S is removed. The rest bypasses the absorber and is
directly routed to the recycle compressor drum. This bypass allows for control of H2S
concentration. In the HP amine absorber, the gas is washed by 25%wt.
1. STRIPPING
The liquid hydrocarbon phase of the cold separator is the stripper feed. First it is
preheated by the heat exchanger to reach the required stripper inlet temperature. Light
ends and H2S gather at the top of the stripper. Inhibitor is injected in the stripper
overhead line. The stripper outlet compressing three phases is separated in the stripper
reflux drum. The vapour feed to the low pressure(LP) amine absorber and vapour
generated from flashing of rich amine from HP amine absorber is washed by lean
solution to remove H2S. Later the vapour from this section is sent to the LP absorber
drum.
The decanted water from the stripper reflex drum is sent under boot level control to
the washing surge drum. The hydrogen liquid phase is split into reflux which is
returned to the stripper. The stripper feed is fed to the top of the naphtha stabilizer.
This stabilizer is reboiled.
A part of the stripper bottom is sent to reboil the stabilizer bottom and later mixed
with the original stream. Final cooling is achieved in the hydro treated diesel cooler.
The free water contained in the product is removed and routed to the washing water
drum.

2. CATALYST REGENERATION
During catalyst regeneration a mixture of nitrogen and oxygen is circulated by the
recycle compressor through the reaction section. The reactor effluent is neutralised by
the injection of ammonia before being cooled. Caustic soda is also pimped by the
washing water pump into the mixture to control the salt deposit. The spent caustic
soda is sent for recycling. The make up oxygen in the system is made by plant air
through the make up compressor.
Reactions:

Elimination of Sulphur

Elimination of nitrogen and oxygen

Elimination of metals

Saturation of olefins and diolefins

PLANT CAPACITIES
DHDS
Unit design capacity : 2.43MMTPA
Unit actual capacity : 2.43MMTPA

LPG MEROX
Design capacity: 35.9 m3/hr LPG

CRN MEROX
Design capacity: 86.8 m3/hr

ATF MEROX
Design capacity: 39.28 m3/hr

PRODUCTS
Hydro treated diesel, Stabilized Naphtha, Rich Amine and fuel gas from LP absorber,
sour water, Desulphurised diesel.

MS BLOCK
The main objective of MS block is to hydro treat straight run naphtha and heavy run naphtha
from CDUs and even from VBUs and removal of sulphur , nitrogen and other impurities from
the feed. Each unit of MS block has targeted qualities of octane number, olefins content,
aromatics content, parrafins content which is blended in the MS pool.
MS block consists of five major units :
1. NHT
2. NIU
3. CCR platforming
4. CCR cyclemax
5. FCC NHT
MS-BLOCK BLENDS FOR ITB CASE
8.33 MMTPA

LEGEND :MTPA (TPD){kg/hr}

LT. NAPHTHA TO NAPHTHA POOL 181 (543) {22625}

918(2754)
{114750}

ISOM FEED
162.5 (487.5) {20313}

109
11.0

NIU

HVY.ISOM.45.17 (135.5) {5646}

72
45

EXPORT
NAPHTHA
117

LT.ISOM.104.5 (313.4){13058}

NHT

NSU

2.33(6.98){291}

GAS TO SRU INT

OFFGAS 0.91(2.7){113}

CCR

573(1719)
{71625}

LPG 17.5 (52.4){2182}

CCR H2 GAS GROSS 43.5
NET H2 GAS EXPORT
29.15(87.5){3644}

LT. FCC NAP 303 (909){37875}

196
84

PRIME G+
SHU

LPG FROM MS BLOCK: 31.8

PRU LPG : 172
TREATED LPG : 150
TOTAL LPG : 353.8

FCC
NSU

GAS TO SRU INT

20

66

REGULAR
MS
263

87
42

PRIME G+
HDS
HVY. FCC NAPHTHA
385(1155) {48125}

PREMIUM
MS
390

68

90
7.76 (23.2) {970}

1.03 (3) {129}

42

REFORMATE 511 (1533){63885}

14.35

FCC NAPHTHA
688(2064){86000}

DOMESTIC
NAPHTHA
120

OFFGAS 1.72 (5.2) {215}

LPG 14.4 (43.2){1799}

3.23 (9.7) {404}

SRN+HN
FROM CDUS

GAS TO SRU INT

DHDS NAPHTHA

225
HVY. FCC TREATED NAPHTHA
385(1155){48125}

153
230

EURO-II
MS
650

30

NHT
Equipment
HDS reactor , stripper, charge heater, splitter and splitter reboiler
Schematic sketch of NHT
Feed surge
drum

NHT reactor

Cold sep

Heater

Make-up Hydrogen +
Recycle gas
Off gases
Stripper

Light Naphtha to ISOM

Unit
Naphtha
Splitter
Heavy Naphtha to CCR unit
10

Process
The sulphur present in the straight run naphtha is removed in the presence of hydrogen and
catalyst in the reactor maintained at desired temperature high pressure .Hydrogen sulphide
generated in the process is removed by stripping. Sweet naphtha splits into light naphtha(
feed to isom) and heavy naphtha(feed to CCR ) in splitter.

Unit process flow description

1. Feed
SRN an heavy naphtha from CDU is stored in feet surge drum and send to the reactor
by centrifugal pumps.
2. Reactor
Naphtha from the pumps is combined with hydrogen rich recycled gas from the
recycled gas compressor.
The combined feed is preheated by reactor stream by a set of heat exchangers. Then
it is further heated in a heater to the required temperature for the activation of the
catalyst. Then it is send to the NHT reactor. The NHT reactor removes sulphur,

nitrogen and other contaminants from the feed with the help of down flow catalyst
bed.
The catalyst used are aluminium and compounds of Ni and Mo. Reactor effluent
passes through the product condenser to condense naphtha vapours to low
temperature to recover naphtha and then enters the separator.
The separator is provided with water wash to wash off the salts and then separated
into 3 phases that include liquid naphtha , sour water and hydrogen recycle gas .
The hydrocarbon liquid from the separator is routed to stripping section to stripper
feed bottom exchangers where it is preheated. The sour water is send to sour water
stripper. The hydrogen recycle gas is recycled by a recycle compressor to combine
feed exchanger.
3. Stripping section
The hydrocarbon liquid from the separator is reboiled in a reboiler using VHP steam.
It is then sent to the stripper where H2S, water traces , light hydrocarbons , hydrogen
is stripped off at the bottom. The overhead vapour is sent to air cooler and then to the
stripper receiver where the vapour is sent to the splitter. The lighter hydrocarbon
collected from the stripper receiver is returned back to the stripper. Then any water
molecules condensed is routed to sour water stripper. The off gas from the splitter
receiver is removed under high pressure control to SRU.
4. Splitter section
The splitter splits hydro treated naphtha to light naphtha which is sent to the NIU unit
feed and heavy naphtha to CCR platform unit.
The splitter overhead vapours from top naphtha splitter is condensed by the
condensers and cooled. It is then sent to the splitter overhead receiver which is
pumped has light naphtha. A part of light naphtha is sent to NIU unit and other part is
pumped back to the splitter.
The splitter bottom is also divided into 2 streams. One part of the stream is sent to the
splitter reboiler, the other part is cooled in exchanges and the heavy naphtha
temperature is dropped to the atmospheric temperature and then sent to storage.

Plant capacities
Design capacity : 1.154 MMPTA
Feed rate : 215 m3/hr

NIU
Objective
Isomerisation of light hydro treated is carried out in series of two fixed bed reactors. Benzene
hydrogenation is highly exothermic , so separate bed reactor, installed upstream of two
isomerisation reactors. To limit temperature across hydrogenation reactor a part is cooled is
recycled to reactor.
The C5 or C6 isomerisation converts C5 /C6 parrafins to isoms and higher octane branched
arrangement over Pt catalyst in presence of hydrogen.
Reaction depends on equilibrium operations conducted . The low octane methyl pentanes and
unconverted n-hexanes are recycled back to the isomerisation reactor to achieve RON 88.5
minimum accuracy to estimate value.
Stabiliser column is used to remove light ends from reactor and remains effluent to
deisohexaniser (DIH)
DIH is used for removing and recycle low octane methyl pentanes and unconverted nhexanes . 2,3 dimethyl butanes , 2,2 dimethyl butanes and 2 methyl butanes are sent to MS
pool and bottom stream to LPG recovery.
The stabiliser reflux drum contains LPG, hydrogen, chloride which is sent to LPG recovery
via caustic scrubber where chlorides are removed by neutralisation with caustic soda.

EquipmentHydrogenation reactor , isomerisation reactors, flash drum, stabiliser column, deisohexaniser,

hydrogen dryers. Naphtha dryers, LPG separator drum, Scrubber drum,H2 gas compressor.

C4 ISOMERIZATION

C5 AND C6 ISOMERIZATION

Process
The objective of isom unit is to process light naphtha from NHT to obtain high octane
number gasoline. Benzene content in light naphtha will reduced to cyclohexane in the
hydrogenation reactor and n-paraffinic HC present in light naphtha get converted into
isoparrafins by isomerisation reaction. LPG and fuel gas are the by products in the process.
Light isomerate and heavy isomerate are the products from the unit which are routed to
gasoline pool of the refinery.

Unit flow description process

1. Dryer section
The light naphtha is fed to the feed surge drum is pumped into the dryers in series.
Feed dryers protect the isomerisation catalyst from moisture air and water which
deactivates or poisonous to it.
Hydrogen from the CCR is taken to the knock out drum and then compressed and
cooled. Part of it is sent to FCC-NHT.
Dried hydrogen is mixed with dried naphtha and sent to benzene hydrogenation
reactor.
2. Hydrogenation section
Combined two phase fed is preheated in reactor and mixed with diluents recycle from
hydrogenation reactor and then heated by HP steam to reaction temperature.
Benzene is hydrogenated to cyclohexane which is highly exothermic reaction and
then sent to flash drums. A part of it free from benzene is sent to isomerisation
reactors.
Incase of high benzene content, the diluents is cooled to control isomerisation reaction
temperature. Diluents recycle should not exceed
30 oC for exothermicity in hydrogenation reactor.
3. Isomerisation reactor
Isomerisation reactor feed from flash drum is mixed with hydrogen and small amount
of chloriding agent in order to maintain chloride balance on isomerisation catalyst .
the first stage isomerisation reactor converts C5 into methyl butanes which is then
cooled and set to second stage isomerisation reactor. In the second stage reactor C6
are converted to methyl pentanes which are further converted to di methyl butanes
and enters the stabiliser .
4. Stabilizer section
C1 to C4 hydrocarbons are removed from the top of the column. LPG , hydrogen, HCl
are stripped off to LPG recovery section via caustic scrubber. The bottom is sent to
deisohexaniser column via chloride bed where the chloride is removed.

5.

Deisohexaniser
The feed from the DIH ump is pre heated and fractionated into 3 columns. The top
part is the light isomerate which is stabilised in the MS pool while the bottom is the
heavy isomerate which consists of 7 , C6 and naphthenes which is sent to LPG
recovery section for lean oil makeup.
The low octane methyl pentanes and n-hexanes are recycled back to the reactors.

6. Scrubber section
It is caustic treated and water washed before being release to LPG recovery section.
The off gas enters bottom of the caustic scrubber. The gas leaving caustic wash
section is washed with water to top pa section to remove entrained caustic and then to
LPG recovery section.
7. LPG recovery section
The dry off gas is sent to LPG refrigeration system and then to LPG separate drum
where it is separated as gas and liquid phase. Stabiliser and lean gas gives LPG.
8. Dryers regeneration
The naphtha feed and hydrogen scrubber off gas are sent to respective dryers in series.
Feed H2 scrubber of gas dryers are regenerated to vaporised deisohexaniser distilled.
9. Chloride injection facilities
For isomerisation reactions tetra chloro ethylene , C2Cl4 is recommended as chloride
agent. , C2Cl4 is converted into HCl and with the addition of NaOH is converted into
NaCl which is removed in the caustic scrubber.

Plant capacities
Design capacity : 0.229 MMPTA
Feed rate : 42 m3/hr

CCR
Equipment
CCR reactor, Stabiliser, De ethaniser, Charge heater, inter heaters, cyclemax
regeneration section.
The objective of CCR unit is to process straight run gasoline to obtain high octane
number gasoline.

Process.
Naphthenic and paraffinic HC present in heavy naphtha get converted into aromatics
by catalytic reforming reactions in platformer at desired temperature and low pressure
in presence of platforming catalyst. Hydrogen and LPG are by products in this
process. Stabilized reformate is routed for blending of motor spirit. Catalyst
deactivates in the reaction due to coke formation and the same can be regenerated
continuously in CCR cycle max regeneration section and reused.

CCR Platforming
Objective
n-parrafins and iso parrafins are converted into cyclo pentanes and then into
cyclohexane and thus aromatics needed for MS pool.
More amount of naphthenes and less amount of parrafins are needed for production
of aromatics.
In reactor aromatics pass unchanged but naphthenes get cconverted to aromatics .
main carbon used are C6-C7. Rich naphtha feed is used from NHT.
Hydrogen rich gas from DHDS ia imported to start CCR platforming.

Unit flow process description

1. Feed section
Heavy naphtha from NHT bottom splitter is preheated by reactor effluent and
treated with sulphur injection, perchloroethylene injection and cold condensate
injection.
Chloride needed to maintain acidic sites for catalyst for isomerisation reactions to
occur and water to distribute chlorides throughout catalyst. The reactor effluent
moves in one direction while cold stream moves in opposite direction in heat
exchanger thus leading to heat transfer in feed .the hydrogen rich gas is heated up
to maintain hydrogen/hydrocarbon ratio for catalyst.
2. Reactor
Catalyst stability should be maintained. Steam generation from the flue gases in
heaters to HP and MP steam. It consist of four reactors :
a. Interheater no 1
b. Interheater no 2
c. Interheater no 3
d. Charge heater
Effluent from each reactor stage is heated and enters the next
reactor to maintain temperature . hydrogen gas is stacked back
and sent for recycle. Gas stream hydrocarbon is purged and
spent catalyst is sent for regeneration of CCR section.
The cold effluent from the reactors is sent to the separators.

3. Separator
The cold effluent is separated as hydrocarbon stream and hydrogen rich gas.
In the hydrogen rich gas part of it is sent as recycle to reactor and CCR
regeneration section, while remaining of the gas is cooled off and sent to
recontacting section. The hydrocarbon stream from top is sent to recontacting and
fractionation.
4. Recontacting section
The hydrogen C1,C2,C3,C4,C5 from the separator is sent to the recontacting
section. It enters the first stage reactor where it is cooled and the gas coming from
the first stage discharge is sent to second stage reactor where is again cooled and
sent to second stage discharge. The liquid from the first and second stage
discharge and the liquid hydrocarbon from separator is sent to the stabilizer.
The off gas coming out of second stage discharge is routed to remove chlorine and
the sent to LPG recovery section by adding propane to chiller and above product.
5. Stabilizer
The product is preheated and then sent to stabilizer column where overhead gas is
recycled to first stage suction drum , overhead liquid in which some part is sent
back as reflux and other part is sent to de ethaniser and then to chloride unit to
recover stabilised LPG as bottom product and while the bottom rich reformate to
sent to MS pool.
The catalyst used is chlorided Al base . the reformates consists from C5 .

CCR cyclemax
It consists of catalyst regeneration and catalyst circulation.

1. Catalyst regeneration
It basically includes :
a. Coke burning
b. Oxychlorination
c. Drying in regeneration tower
d. Reduction zone

2. Catalyst circulation
The catalyst is transformed from platforming reactor to regeneration reactor.
Spent catalyst flows from bottom of last reactor to catalyst collector.
Circulators N2 from lift gas blower engages catalyst lifts to disengaging
hopper .in hoper fine removal blower separates the additional fines and
nitrogen from catalyst from the top gas. Fines are collected in the dust
collector and nitrogen circulates back.
Whole catalyst drops from regeneration tower by gravity to nitrogen seal drum
and then to lock hopper. Then the hydrogen rich gas from recontact engages
catalyst and lifts it through catalyst lift line in regeneration zone to top of first
reactor and then catalyst collector.
The spent catalyst is the catalyst that leaves reactor purged to remove
hydrocarbon . Catalyst environment is changed from hydrogen to nitrogen
and done during lift operation of catalyst from bottom of reactor to top of
regeneration.
The regenerated catalyst environment is changed from nitrogen to hydrogen
from bottom of regenerator to top of reactor.
Regeneration tower catalyst passes through :
a. Burn
b. Reheat
c. Chlorination
d. Cooling zones
e. Drying
Two ways to operate regeneration :
1. Black burn
The burn and reheat zone contains oxygen while chlorination, drying,
cooling contains N2 . It is used when coked catalyst is in chlorination,
drying, cooling zone and restarting regeneration tower.
2. White burn
The burn and reheat contains oxygen while chlorination, drying,
cooling zone contains air. It is operated in regeneration tower.

Oxychlorination needs air and chlorine. It is used to redisperse metals

after burning and adds chlorine to catalyst. After black burn no coked
catalyst should go into zone and it be devoid of coke and then white
burn is started. It is important to start regeneration in white burn if
there is a risk of coked catalyst below burn zone. Otherwise high
temperature will lead to catalyst phase change and loosing activity.

Plant capacities
Design capacity : 0.769 MMPTA
Feed rate : 110 m3/hr

FCC NHT (PRIME G+)

Equipment
Feed surge drum, Selective hydrogenation unit reactor, Splitter column, HDS reactor ,
Stabiliser, Amine absorber etc.

Objective
The objective of FCC NHT is to process FCC gasoline to obtain product streams(Light
gasoline and heavy hydrotreated gasoline ) with targeted qualities of octane number, sulphur
content, benzene content and olefins content. Prime G+ provides us to meet EURO3/EURO-4 specifications of gasoline wrt :
Diolefins : nil
Olefins : 18% Max
Sulphur : 50 ppm
Benzene : 1%

Schematic sketch of FCC NHT unit

Light FCC gasoline to MS pool

SHU

FCC Naphtha
Splitter
Unit

HDS

Heavy FCC gasoline to

MS pool

21

Process
FCC CRN from FCCU unit is taken to the unit as hot feed. The CRN is taken to the feed
surge drum. CRN is then pumped to a series of heat exchangers and enters into selective
hydrogenation unit reactor. The purpose of the reactor is to convert diolefins to olefins and to
convert Mercaptans and lighter boiling sulphur compounds in the feed to higher boiling
sulphur species.
The outlet from the SRU reactor is routed to splitter where light naptha, heart cut naphtha and
heavy naphtha is separated. Light naphtha is directly routed to MS pool where as heart cut
naphtha which is rich in benzene content is routed to NHT unit.
The bottom heavy naphtha is passed again through series of heat exchangers and routed to
hydrodesulphurisation reactor (HDS reactor). Here the sulphur of the heavy naphtha is
reduced to allowable extent and the Desulphurised heavy gasoline (HCN) from the HDS
reactor is routed to naphtha stabiliser. The HCN is stripped off any dissolved H2S or lighter
compounds like C1.C2s and the stable HCN is routed to final refinery MS pool.

Unit process description flow

1. Selective hydrogenation unit
The feed from the FCC CRN and FCCU is preheated and send to feed filter. From
the feed filter it goes to SHU feed surge drum where the pressure is controlled and
pumped to SHU feed pumps. H2 makeup from the unit is mixed with the fresh feed.
Then it enters the tube side of SHU feed and the mixture is heated by the heat of HDS

effluent. It then enters the SHU pre-heater and at proper reactor inlet temperature it
flows to SHU reactor where the hydrocarbon mixture is heated. The SHU reactor
consists of 2 beds catalyst to optimise and provide selective hydrogenation of
diolefins in feed and convert light Mercaptans into heavier boiling temperature
sulphur compounds. The SHU feed filter then enters the splitter.
2. Splitter section
The splitter section consists of 52 trays. The feed enters at the 19th tray from the
bottom where it is fractionated to produce LCN and HCN. The splitter overhead is
condensed by air cooling in the splitter overhead air condenser. Vapour is separated
from the reflux liquid in splitter reflux drum. The splitter is again condensed and the
vapour is purged by split range control of pressurising hydrogen and venting the fuel
gas header. The reflux is then pumped to the pump by splitter reflux. The tray number
48 accumulator gives LCN which is cooled and stored. The splitter bottom is reboiled
by steam and heavy naphtha is sent to HDS unit. In tray number 36 benzene heart cut
is obtained which is cooled by air cooler and sent to storage.
3. HDS [Hydro Desulphurisation Unit]
Heavy naphtha from the splitter enters the HDS feed drums which is mixed with
recycled hydrogen. The HDS feed effluent is then divided into 3 beds where it is
heated and the inlet temperature is controlled by fuel gas and the bottom product leads
to hydrocarbon liquid. The heater is simultaneously cooled by HDS effluent cooling
air and washing water injection to flush salt deposits formed.
A part of hydrocarbon liquid is sent back to the HDS and the other part is sent to the
stabiliser section. The vapours from the stabiliser section are sent to the amine
knockout drum which is free from condensed liquid hydrocarbon by the help of
demister. From the knockout drum it enters the amine absorber where it is pre-heated
to maintain 100C and then contacted with DEA solution to remove H2S gas. The H2S
enriched DEA is sent to DEA regeneration unit where the part of the gas is purged to
fuel gas while the other part of the sweetened gas is mixed with hydrogen maker and
sent to recycle compressor knockout drum and back to HDS reactor.
4. Stabiliser section
The liquid is heated by the stabiliser feed bottom and sent to the stabiliser column. A

part of the liquid phase is cooled in the stabiliser overhead cooler and then sent to the
stabiliser reflux drum, while water phase is sent to the sour water treatment and in the
vapour phase the pressure is controlled by the gas flow. The other part of the liquid
phase coming from the stabiliser bottom is reboiled by VHP steam bailer which is
separated into 2 streams. Then the bottom product is treated and sent to MS storage
pool while the other part is cooled by stabiliser feed and heavy gasoline is obtained
which is recycled back.

Plant capacities
Design capacity : 0.893 MMPTA
Feed rate : 140 m3/hr

POWER AND UTILITIES

The main plants in utilities are :
1.

Raw water systems

2. De mineralised plant
3. Power plants I &II
4. Captive power plant
5. Cryogenic nitrogen unit
6. Flare system

1. Raw water systems

Raw water is received from Tatipudi, Raiwada and Mindi reservoirs. There are high
lift pump house and low lift pump house for sourcing sea water for cooling process
streams and fire fighting systems.
There are cooling water towers to provide cooling water to cool equipments. Drinking
water plants to satisfy drinking water demand in refinery.
The water system from Yarada bore well was used but stopped later on due to the
contamination of ground water system.
There are 3 types of water systems:
a. Raw water system
Water from Tatipudi and Mindi is sent to the de mineralised plant and power plant
I depending on the equitability of water. If the pump is tripped or failed,
alternative sources are used and maintenance is done.
b. Service water system
It was installed during the time of VREP I and VREP II. From PP I service water
is sent to VR and VREP II and then sent to CDU I, CDU III, FCCU, flairs and
desalters. From VREP I service water is sent to desalter CDU II and BBU.
c. Drinking water
The drinking water consists of PSF and activated carbon filters. Filtered water is

chemically dosed and stored in drinking water sump. In sump NaOCl is added to
kill bacteria and free residual chlorine is maintained.

2. Demineralised plant
Equipment:
Sand filter, Strong acid cation , Weak base anion, Strong base anion, Degasser ,
Mixed bed.

Process:
Raw water is processed in ion exchangers to get demineralised water. The latest
technology used in VRCFP for demineralising water is reverse osmosis. Morpholine
is used to maintain pH of water.

Unit process flow description

1. Alum dosing tank
There is a mixer and level gauge, depending on how raw water is analysed
percentage of aluminium dosage is prepared and used. Suction line is provided
with strainer.
2. Alum dosing pump
Flow adjustment depends on raw water turbidity. For light particles dosing is not
enough so poly electrolyte is added. In laboratory alum dosing quantity is
determined to have better filtration in PSF.
3. Sodium sulphite dosing tank
Mixer and level gauge, suction line are provided with strainer.
4. Sodium sulphite dosing tanks
Delivery line is connected to PSF inlet.
5. PSF [pressure sand filters]
To measure the differential pressure a DP indicator is used. In PSF mechanical
filtration of coagulated raw water is achieved and turbidity is reduced. Non ionic

and suspended impurities like dirt, salt and mud is removed.

6. SAC [strong acid cation]
There are 2 co-flow operation pipes and 1 counter current regeneration. After 10
cycles or when DP is greater than 0.8kg/sq cm it is back washed.Ca2+, Mg2+, Na+
are removed by exchange of H+ ions in the resins and convert into acids. It is
then passed through degassed tower.
7. Degassed tower
The water devoid of cations is passed to degasser air blower.
8. Degasser air blower
Low pressure and high velocity is maintained here. Degasser water is sent from
top to bottom of the blower while the air from bottom to top. When H2CO3 comes
in contact with O2 and splits as water and CO2 which blows out of the vent hole.
Residual free CO2 is maintained in degasser storage tank.
9. Degasser water storage tank
It is an inlet to air blower and outlet to water pumps degasser.
10. Degasser water pumps
There are 3 service pumps and 1 standby pump. The degassed water is transferred
to WBA/SBA for further ion exchange. A part of water is sent to SAC for
regeneration.
11. WBA [weak base anion]
There are 2 pipes in service and 1 in standby for regeneration. It exchanges load
such as Cl, NO3, SO4 from degassed water. Outlet is checked by conductivity test.
12. SBA [strong base anion]
Weak acids such as leakages from degasser, traces of chlorides and silica is
exchanged to OH form. It is then sent to MB polisher units.

13. Mixed bed

Anion and cation resins are in mixed form. Due to differences in specific gravity
both cation and anion resins are separated in back wash. First anion resin is
regenerated and then the cation resin. Both resins are then mixed with mixed bed
blower and anions are trapped in resins. It is then stored in DM storage tank.
14. DM storage tank
The demineralised water is stored here and sent to various units of the plant like
Deaerator, DHDS, CPP etc.
15. Acid day tank
It is used for regeneration of resins.
16. Alkali day tank
It is used for regeneration of resins.

Plant capacities
Design capacity :
DM I : 75 M3/Hr
DM I : 120 M3/Hr
DM I : 180 M3/Hr

3. Power plants
Equipment :
Deaerator , Economiser , Bank tubes , Super heater , CO chamber.

Process :
DM water is processed to generate VHP , MP, HP steam in boilers.
Steam is also generated from the heat conservation of CO. Power plants are mainly
used for steam generation and power generation. Steam is also generated from the
flue gas from the gas turbine gas generators. PP I consists of WIL- 8 , BHPV, NCO ,
IBH-9, IBH-10 boiler . PP II consists of WILB , CO, BOP boilers. Water from DM

plant is sent to Deaerator where dissolved oxygen present is water is removed by HP

steam and then sent to boilers in PP I & PP II.
PP I generates HP, LP, MP steam for CDUs, Desalter, FD fans for boilers.
PP II generates HP, MP steam for deaerators , oil burners and heating systems.

Unit process flow description of boilers :

In a boiler the upper drum is called the steam drum and the lower drum is called the
mud drum which are connected by bank of tubes.
The water cooled furnace wall is welded along with the tube tank. The main tube tank
forms one side of the furnace and the water wall tubes cover the opposite wall. The oil
burner is mounted on brick lined wall in boiler front area. The furnace front is fixed
and is free to expand in the rear along the length of the drum. The furnace D wall
tubes joining both steam and mud drum, and located on the roof as well as floor of the
furnace cool the refractory.
Superheater is of single element drainable type. It is located between the upper and
lower drums at the end of the furnace. Combustion gases pass over superheater
element before entering the main tube tank .It is also called the conventional radiation
section. Dry saturated steam from the steam drum passes through the inlet header of
superheater via super heating connecting pipes by absorbing the convection heat. The
saturated steam gets converted into superheated steam. It then passes to the main
steam line.
The economiser is located in the second pass of the boiler. The tubes bare are
arranged in horizontal rows. At tube circuits originates from inlet header and
discharge to outlet header. Feed water is supplied to the economiser inlet header and
after being preheated goes to the steam drum. In the process, waste heat is recovered
from the flue gases.
Boiler tank tubes, water wall tubes and the furnace wall tubes are rolled into the
drums by expansion. Other connections like feed water line, safety valves and
saturated steam are strength welded to drums.
Steam drum capacity is more than that of mud drum. It is large enough to provide
adequate storage capacity and minimise water level fluctuation causing out of sudden
change in steam demand. It is also provides space for internals. The objectives of
drum internal is to reduce the moisture content in saturated steam leaving drum by

mechanical means. This helps in reducing the proportion of solid content in steam and
sending a dry saturated steam to the sulphur heater. Steam that enters the drum is
collected in the compartment formed by baffles. The baffles completely reverse the
direction of flow. In the process, steam loses most of its entrained water. Thereafter it
flows over the corrugated sheet. The provides steam with tortuous path and thereby
forcing any remaining entrained water against corrugated plated. Since the velocity is
relatively low water cannot be picked up again and therefore runs down the
corrugated plate and returns to the lower part of the drum.
The direction of steam si reversed again before entering the series of holes in dry box.
Dry steam leaves the drum through inlet nozzles.
In addition to the water separation system, the internals also consist of feed water
distributing pipe running along the length if the stream drum, blow down piping
which has uniformly pitched smaller diameters holes through which a portion of water
of high solid can be tapped off. Gauge glass to detect water level and a main blow
down piping connected to the mud drum.
Fuel gas leaving the economiser enters the stack through a duct, which is provided
with a damper and a discharge to the atmosphere.
Soot blowers are provided to remove the soot deposited on the tubes. Soot is removed
to increase the heat transfer and also to avoid local and secondary burning.
In the rotary blower remains in the boiler at all items supported by element bearing
usually attached to the booster tubes. Specially designed nozzles are located on the
element for each specific installation . dry saturated steam is used as blowing medium
to prevent penetration of corrosive fuel gases through the element to the head valve a
scavenging air check valve is furnished. The soot blowing element is driven by a
motor.

Plant capacities :
PP I :
WIL 8 : 50 T/Hr
BHPV : 50 T/Hr
NEW CO : 40 T/Hr

PP II
CO : 60 T/Hr

4. Captive power plant

Equipment :
Gas turbine generators , Deaerator, HRSGs ,Economiser , bank tubes ,Super heater

Process:
Naphtha is used to run a gas turbine generator and thus produce power to cater the
demands of the whole refinery.
This also helps to generate steam using flue gas from GTGs .
It is used in cogeneration of steam and power leading to more energy efficient use of
fuel as compared to a conventional power plant. The fuel used is 4 naphtha tanks and
2 diesel tanks to supply for GTGs.

Unit process flow description :

1. Gas turbines
MS3002 is for GTG 1 & 2 in VR. The equipments used are diesel engine, torque
convertor, accessory gear box, gas turbine, load gear box, generator, complete set
of lube oils. High pressure air is added to one side of compressors while in the
opposite direction fuel addition takes place in the combustion chamber. The
combustion consist of 15 stage compressors and 6 combustion chambers and
products are directed to nozzles under high pressure turbines. Gases from high
pressure are reduced to low pressure and given out. MS5001 is for GTG 3 & 4 in
VREP I. This consists of 17 compressors and 10 combustion chambers and 2
stage turbines are used for output.
2. Generators
It is coupled with the gas turbine through gear box that reduces turbines speed.
The DC current enters the generator and then the automatic voltage regulator to
keep voltage constant. The various electrical instruments are 1 KV switch gear,
LT switch gear, 3 KV switch gear, uninterrupted power supply and CT switch
gear.

3. Heat recovery steam generator

Deaerator provides water for HRSGs. They are used to recover heat from turbine
exhaust gases. They is natural circulation single pressure horizontal duct fired
water tube boiler. The firing facility is also and steam production in HSRG is
done. The power from CPP is supplied to DM plant, feed water facilities and
Deaerator .

PLANT CAPACITIES
GTGs : 7.18 & 21.31 MW
HSRGs : 27 & 60 T/Hr

5. Flare system
Equipment:
Flare tip, Flare stack, Fluidic seal , Flame front generator, Water seal drum, Knock
out drum , Blow down pumps

Objective :
Flare facilities are provided in order to avoid releasing of in burnt hydrocarbons to the
atmosphere. Facilities exists for injecting steam to stack for smokeless flare for
refinery.
In view of additional hydrocarbon load subsequent to VRCFP commissioning,
additional flare facilities are provided in order to avoid releasing of un- burnt
hydrocarbons to the atmosphere.
This flare system also comprise of a separate AAG flare which is non smokeless type.
The liquid hydrogen discharges and separates to slop tank and knock out drums.
The existing system consists extremely toxic gases coming from VR & VREP I. CDU
I, CDU II, FCCU I. FCCU II, FCCU III & PRU total load is 698.5 tonnes/hr.

Unit process flow description

1. Collection of gases
Gasses from CDU III, VBU, FCCU I, PRU, SRU, DHTS, CDU II, FCCU II, CDU
I are passed from the headers to the final knock out drum and then condensed
hydrocarbon is separated in the KO header to water seal drum and then the gases

go to the flare stack where it is burnt. The flare seal is at stream of flare tip.
2. New flare knock out drum
It is used to trap liquid droplets. Knock out drum receives liquid and vapour where
the liquid droplets are trapped in the KO drum and vapour goes away. Water is
recovered by slope tanks blow down pumps.
3. Blow down pumps
They are motor driven centrifugal pumps. The hydrocarbon liquid in the KO drum
is given to the slope header where BCW requirement is controlled.
4. Water seal drum
Water seal drum is situated at the base of flare stack. It maintains pressure in flare
header to prevent flame flash back. The water is supplied continuous and level is
maintained and entry of air is restricted.
5. Flare stack
The top point is sent to the flare tip while the bottom is sent to flare system
bottom. Then it is sent to check O2 in gases. Continuous flue gas purge is provided
to keep pressure constant.
6. Flare seal
It is a gas lead pipe and it has an inverted cylinder over the lead pipe. The top of
the cylinder is closed while the bottom is opened. The lighter gases are collected
in the upper bend while heavier gases settle down in the lower bend.
7. New flare tip
The tip is on the top of flare system. The upper part of tip is high heat resistant
stainless steel and remainder is carbon steel. The flame is retained at emission
rates. The 3 pilot burners are equally spaced. Then the upper manifold injects
steam into flame at the tip outlet to promote smokeless combustion.
8. New flame font generator
For ignition of pilot, this is installed. It does gas and air mixing, it has a separate

valve foe gas and air and 3 valves to direct ignition.

Plant capacities
New flare : 698.5 MT/Hr
Old flare : 284.716 MT/Hr
VRCFP flare : 490.6 MT/Hr

6. Cryogenic nitrogen unit

Equipment:
Air compressors, moisture separator, air purification unit, regeneration reactor,
distillation column, expansion turbine, heat exchangers, cold box, vaporisers.

Process :
1. Air suction and compressor
Air suction filter is compressed by main air centrifugal compressors to control the
pressure.
2. Air pre-cooling
The shell and tube heat exchangers cool the air by chilled water and the moisture
separator condenses water and separates moisture and sends the dry water to the
knock out drum. The cooling water which is cooled by waste N2, comes out of
cold box in the evaporation cooling tower. The chilled water is pumped into after
cooler and the return water is circulated back to evaporation cooling tower where

the losses are balanced.

3. Drying
Chilled air is passed to the adsorber where saturated moisture , CO2 are removed
by using aluminium and molecular sieves.
4. After filters
After elimination of aluminium and molecular sieve dust the degeneration steam
is mixed with waste air from cold box and heated. The hot gases passed through
the sieves to regenerate absorbents.
5. After cooling
Purified air is cooled down by return gases in heat exchangers. Cooled by GAN
the waste gases from condenser return to the turbines.
6. Distillation
In the distillation column O2 rich liquid and gaseous N2 is obtained from bottom
and top of the distillation column respectively. The rich liquid is throttled and then
vaporised and then condensed.
7. GAN & LIN
A part of GAN obtained from the top part is warmed to ambient temperature while
other part is condensed thus obtaining liquid nitrogen. A part of the bottom LIN is
sent to LIN high pressure storage system while other part is sent as reflux back to
the column,

Plant capacities
Design capacity : 245 Nm3/Hr