NATIONAL INSTITUTE OF TECHNOLOGY SIRNAGAR (JAMMU & KASHMIR)

INDIAN OIL CORPORATION LIMITED (An ISO 9001:2000, ISO 14001 & OSHAS 18001 Certified Company)

BARAUNI REFINERY In Harmony with Nature

INDUSTRIAL TRAINING PROJECT REPORT Period of Training: - 15/12/2015 to 14/01/2016

SUBMITTED BY:

KESHAV KUMAR (chem/01/2013)BRANCH:- CHEMICAL ENGINEERING.B.TECH. (5TH SEMESTER)

TABLE OF CONTENT1. HISTORY OF IOCL

2. INTRODUCTION OF BARAUNI REFINARY3. FIRE AND SAFETY DEPARTMENT 4. OIL MOVEMENT AND STORAGE (OM&S)5. ATMOSPHERIC VACCUM AND DISTILLATION UNTI (AVU)6. CTALYTIC REFORMING UNIT (CRU)7. BARAUNI EXTENSION PLANT (BXP)8. MOTOR SPRIT QUALITY UNIT (MSQU)9. CONCLUSION

Indian Oil Corporation has four divisions:

1. Marketing Division with Headquarters at Bombay 2. Refineries and Pipelines Division with Headquarters at New Delhi 3. Assam Oil Division with Headquarters at Digboi 4. Research and Development Centre at Faridabad

Services:

1. Refining 2. Pipelines 3. Marketing 4. Training 5. Research & Development

Indian Oil Corporation Ltd. is India's largest company by sales with a turnover of Rs. 271,074 crore and profit of Rs. 10,221 crore for the year 2009-10. Indian Oil is the highest ranked Indian company in the latest Fortune ‘Global 500’ listings, ranked at the 98th position (2011).

BARAUNI REFINARY INTRODUCTIONS Objective:

The establishment of a totally electronic-based communication system within the refinery. To set up eco-friendly refinery, as indicated by a green belt outside it.

Structure of the refinery :- The consist of the following important sections.

1. Production Department: 2. Engineering service department:3. Internal Audit: 4. Inspection Department: 5. Fire and Safety Department: 6. Technical Service: 7. Quality Control Department:

NAME OF PROCESSING UNIT 1. AVU-1 : ATMOSPHERIC & VACCUM UNIT-12. AVU-2 : ATMOSPHERIC & VACCUM UNIT-23. AVU-3 : ATMOSPHERIC & VACCUM UNIT-34. CCU : COKE CALCINATION UNIT5. NSU : NAPTHA SPLITTER UNIT6. CRU : CATALYTIC REFORMING UNIT7. RFCCU : RESIDUE FLUDISED CATALYTIC CRACKING UNIT8. DHDT : DIESEL HYDRO TREATING UNIT9. HGU : HYDROGEN GENERATION UNIT10. SRU : SULPHUR RECOVERY UNIT11. ARU : AMINE GENERATION UNIT12. MSQU : MOTOR SPRIT QUALITY UNIT

MAIN PRODUCTS 1. LPG : LIQUIFIED PETROLEUM GAS2. MS : MOTOR SPIRIT3. NAPTHA : NAPTHA4. HSD : HIGH SPEED DIESEL5. SKO : SUPERIOR KEROSENE OIL6. MTO : MINERAL TURPENTINE OIL7. LDO : LIGHT DIESEL OIL8. LSHS : LOW SULPHUR HEAVY STOCK9. RPC : RAW PETROLEUM COKE10. CPC : CALCINED PETROLEUM COKE11. P. EXT : PHENOL EXTRACT12. SL. WAX : SLACK WAX13. ATF : AVIATION TURBINE FUEL14. FO : FURNACE OIL

FIRE AND SAFETYThere are two wings:

a. Fire Protection wing. b. Safety wing.

Different Fire Extinguishing Agent:

1. Water 2. Mechanical Foam 3. Dry chemical powder 4. Carbon Dioxide 5. Steam 6. Vaporizing Liquid

Work Permit System:

1. Hot Permit – for hot jobs like welding, gas cutting, etc. 2. Height permit – to work at heights 3. Soil Excavation Permit 4. Cold Permit

ATMOSPHERIC AND VACCUME UNIT (AVU)Main Products: After passing through the AVU the main products are.

LPG, Propane Light Naphtha

Heavy Naphtha Aviation Turbine Fuel(ATF)Light gas oil(bluish) Heavy gas oilVacuum gas oil Vacuum residue

Units of the AVU: 1. Desalting 2. Crude Oil Distillation Unit (CDU)3. Vacuum Distillation Unit (VDU) 4. Naphtha Stabilization Unit (NSU)

DESALTERObjective: Desalting is a purification process used for the removal of salts,

inorganic particles and residual water from crude oil and thereby reducing corrosion and fouling of equipments.

Feed: Crude Oil from storage tank.

Operating Conditions: Temperature: 130-140°C , Pressure: 11-12 Kg/ sq.cm.

CURDE DISTILLATION UNIT (CDU)Objective: To distillate and separate valuable distillates according to the boiling

point (naphtha, kerosene, and diesel) and atmospheric gas oil (AGO) from the crude feedstock.

Feed: Crude oil from Desalter.

Operating Conditions:

Temperature: 370-380°C.Pressure: 13-15 Kg/ sq.cm.

Top Product: Gasoline, kerosene, Gas oil

Bottom Product: Reduced Crude Oil (RCO)

VACCUM DISTILLATION UNIT (VDU)Objective: To recover valuable gas oils from reduced crude oil via vacuum

distillation technique.

Feed: Reduced crude Oil form CDU.

Operating Conditions: Temperature: 415°C , Pressure: 40- 60 mm.Hg.

NAPHTHA STABLIZATION UNIT (NSU)Objective: To convert the unstable Raw Naphtha obtained from CDU to stabilized

naphtha which can be used to make motor spirit.

Feed: Raw Naphtha obtained from CDU.

Operating Conditions:

Temperature: 120-125°C.

Pressure: 2-3 Kg/ sq.cm.

CATALYTICE REFORMING UNIT (CUR)Objective: The purpose of the Catalytic Reforming unit is to improve octane number of hydro treated gasoline (Ron= 97) and hydrogen rich gas / or to provide aromatics (benzene, toluene, and xylene) for petrochemical plants.Feed: 85-160°C cut Naphtha / Visbreaker Naphtha

Catalyst: Ni-Mo Oxides for NHTU Pt - Sn or Re for Reforming.DIFFERENT SUB UNIT

1. Naphtha splitter unit (nsu)Objective: This unit has been designed to split straight run naphtha.

Feed: Straight run Naphtha.

2.Naphtha hydrotreater unit (nhu)Objective: The purpose of Naphtha hydrotreater is to eliminate the impurities (such

as sulphur, nitrogen, halogens, oxygen, water, olefins, di-olefins, arsenic and metals) from the feed.

Feed: Naphtha coming from the NSU.

RESIDUE FLUIDISED CATALYTIC CRACKING UNIT (RFCCU)Objective: A RFCCU expands the versatility and profitability of an FCC to crack a wide variety of feedstock. To convert Heavy Vacuum Gas Oil to valuable distillates like LPG, Gasoline, Diesel by catalytic cracking in fluidized bed.

Feed: Vacuum Gas Oil/Residual Cracked Oil/Vacuum residue /Hydrocracker Bottom. These feeds arrives here from different units like AVU-I, II, III, OM&S, COKER-A, B.

Catalyst: Silica & Alumina Zeolite Structure.

RFCCU Product : 1. Gas 5. Coke2. LPG 6. Heavy Naphtha3. Gasoline 7. Light Cycle Oil (LCO)4. Slurry Oil 8. Heavy Cycle Oil (HCO)

DIESEL HYDROTREATING UNIT (DHDT)OBJECTIVE: To meet the Euro-Three and Euro-four diesel quality requirement

(350/50 ppm of Sulfur ).

Feed: Straight run diesel/ RFCCU diesel component/ Coker and Visbreaker dieselcomponent.

Catalyst: Ni-Mo oxide( Rice size and shapes)

Chemical Reaction: Desulphurization and Denitrification

THE HYDROGEN GENERATION UNIT (HGU)Objective: The purpose of the Hydrogen Generation Unit is to produce 99.99 vol% purity hydrogen from straight run Naphtha. It also supplies Hydrogen to Hydro-treating Unit (to meet out the centane specific in diesel fuels) and MSQU Unit (to meet the octane and aromatic specification of gasoline fuels). Feed: Natural Gas / Naphtha Catalyst : Co-Mo for Hydrotreater ZnO/K2Co3 for H2S and Chloride adsorber

NiO for Preformer Ni for ReformerCuO for HT/LT Shift reactors Adsorbents (molecular sieves) for PSAHGU Product is 99.99% Pure H2

SULPHUR RECOVERY UNIT (SRU)Objective: To Reduce the SO2 emission from the Refinery by recovering Sulphur

from Amine Acid and Sour Gases produced during various Hydrotreating Process.

Feed: Amine Acid gases and Sour acid gases.

Operating Conditions: Temperature Range: 195-320°C.

Pressure: 0.56 kg /cm2 (g).

MOTOR SPIRIT QUALITY UNIT (MSQU)Objective: To Upgrade the Naphtha by increasing its Octane Number to Higher

Octane/Low Benzene/Low Olefins Motor spirit (MS) Component (Isomerate) to Meet Euro III / IV MS Specifications.

Feed: C5-85 Deg C cut Naphtha /RFCCU gasoline (70-90 deg C cut)

Catalyst: 1.Co-Mo for Hydrotreator Reactor 2.Pt and Ni for ISOM.

Product Yield:

1. Motor Spirit 90 wt % 2. LPG 10 wt %

PRIME G+ PROCESS (PRIME G+)Objective: Removal of sulfur from RFCCU gasoline with minimum octane loss to

meet norms of EURO-IV in MS.

Feed: FCC Gasoline. Total Sulphur in Product: ≤100 ppm

Prime G+ offers flexibly allowing different process configuration to best fit the gasoline pool requirement and also maximize refinery profitability. Naphtha splitter may be optional depending upon the arrangement for maximization of octane loss

NAPHTHA HYDROTREATMENT UNIT (NHDTU)

Objective: Purpose of this Naphtha Hydro Treating Unit is to protect Isomerization catalyst by eliminating or reducing to an acceptable level the impurity of naphtha. It eliminates the impurities such as sulfur, nitrogen, halogens, oxygen, water, olefins, arsenic, and other metals present in naphtha feedstock to have longer life catalyst.

Feed: Naphtha

Catalyst: Platinum Catalyst. (Pt)Nickel Molybdenum (NiMo)

ISOMERIZATION UNIT(ISOMU)Objective : The main objective is to convert n-butane, n-pentane, n-hexane into

their respective isoparaffins of substantially higher octane number.

Feed: Straight chain paraffins (n-butane, n-pentane, n-hexane).

Catalyst: 1. Aluminum chloride (AlCl3) plus Hydrogen Chloride (HCl) for low temperature process.2. Platinum or another metal catalyst for higher temperature process.

ISOMU Products: Branched-chain isomers of straight chain paraffins.

SELECTIVE HYDROGENATION UNIT (SHU)Objective: To remove the unwanted dienes and acetylenes form unsaturated LPG

from RFCCU and Coker unit.

Feed: Unsaturated LPG from RFCCU and Coker unit.

Operating conditions: Temperature: 230 – 340 °F., Pressure: 200- 300 psi.

AMINE RECOVERY UNIT (ARU)Objective: To separate H2S and amine solution form Di-ethanol amine almost

saturated with H2S (rich amine) and received from DHDT, RFCC, HGU unit

Feed: Amine containing absorbed H2S and CO2.

Operating Conditions: Temperature: 45 - 115°C., Pressure: 0.5 – 5 Kg/ sq.cm.

ConclusionsIt was a good experience to be a trainee at Indian Oil Corporation Limited (IOCL) Barauni. Wonderful place to create a correlation as Chemical Engineering of the things which we see in the books very small and externally get a chance to see the things as it is , their constructions , their size , the equipment and get the adequate knowledge of the things for which a lot of contradiction in my mind I have before going there. It has been a very good learning & enlightening experience to do this Vocational Training. As I feel from my personal experience that it must be a part of an engineering curriculum.

THANKYOU