CHAPTER 1 : BARAUNI REFINERY

1145129/8035-11, GTBKIET, Malout

Barauni Refinery

Barauni Refinery was built in collaboration with Russia and Romania. Situated 125 kilometeres from Patna, Barauni Refinery was commissioned in 1964 with a refining capacity of 1 Million Metric Tonnes Per Annum (MMTPA). It was dedicated to the Nation by the then Union Minister for Petroleum, Prof. Humayun Kabir in January 1965. After de-bottlenecking, revamping and expansion projects, its current capacity 6 MMTPA. With various revamps and expansion projects at Barauni Refinery, capability for processing high-sulphur crude has been added, thereby increasing not only the capacity but also the profitability of the refinery.

Barauni Refinery was initially designed to process low sulphur crude oil (sweet crude) of Assam. After establishment of other refineries in the Northeast, Assam crude is unavailable for this refinery. Hence, sweet crude is being sourced from African, South East Asian and Middle East countries. The refinery receives crude oil by pipeline from Paradip on the east coast via Haldia. Matching secondary processing facilities such Resid Fluidised Catalytic Cracker (RFCC), Diesel Hydrotreater (DHDT), Sulphur Recovery Unit (SRU) have been added. These state-of-the-art eco-friendly technologies have enabled the refinery to produce green fuels complying with international standards. The third reactor has been installed in the DHDT unit of Barauni Refinery to produce Diesel that complies with the Bharat Stage-III auto fuel emission norms. The MS Quality Upgradation project of Barauni Refinery is in full swing to supply Bharat Stage-III compliant petrol to the market.

Corporate Overview

Email Print IndianOil is India's flagship national oil company with business interests straddling the entire hydrocarbon value chain from refining, pipeline transportation and marketing of petroleum products to exploration & production of crude oil & gas, marketing of natural gas and petrochemicals. It is the leading Indian corporate in the Fortune 'Global 500' listing, ranked at the 125th position in the year 2010.

With over 34,000-strong workforce, IndianOil has been helping to meet Indias energy demands for over half a century. With a corporate vision to be the Energy of India, IndianOil closed the year 2009-10 with a sales turnover of Rs. 271,074 crore and profits of Rs. 10,221 crore.

At IndianOil, operations are strategically structured along business verticals - Refineries, Pipelines, Marketing, R&D Centre and Business Development E&P, Petrochemicals and Natural Gas. To achieve the next level of growth, IndianOil is currently forging ahead on a well laid-out road map through vertical integration upstream into oil exploration & production (E&P) and downstream into petrochemicals and diversification into natural gas marketing and alternative energy, besides globalisation of its downstream operations. Having set up subsidiaries in Sri Lanka, Mauritius and the United Arab Emirates (UAE), IndianOil is simultaneously scouting for new business opportunities in the energy markets of Asia and Africa.

Reach and Network

IndianOil and its subsidiary (CPCL) account for over 48% petroleum products market share, 34.8% national refining capacity and 71% downstream sector pipelines capacity in India.

The IndianOil Group of companies owns and operates 10 of India's 20 refineries with a combined refining capacity of 65.7 million metric tonnes per annum (MMTPA, .i.e. 1.30 million barrels per day approx.). IndianOil's cross-country network of crude oil and product pipelines, spanning 10,899 km with a capacity of 75.26 MMTPA, is the largest in the country. With a throughput of 68.5 million tones, it meets the vital energy needs of the consumers in an efficient, economical and environment-friendly manner

It has a portfolio of powerful and much-loved energy brands that includes Indane LPGas, SERVO lubricants, XtraPremium petrol, XtraMile diesel, etc. Validating the trust of 56.8 million households, Indane has earned the coveted status of 'Superbrand' in the year 2009.

IndianOil has a keen customer focus and a formidable network of customer touch-points dotting the landscape across urban and rural India. It has 19,463 petrol and diesel stations, including 3517 Kisan Seva Kendras (KSKs) in the rural markets. With a countrywide network of 36,900 sales points, backed for supplies by 140 bulk storage terminals and depots, 96 aviation fuel stations and 89 LPGas bottling plants, IndianOil services every nook and corner of the country. Indane is present in almost 2764 markets through a network of 5456 distributors. About 7780 bulk consumer pumps are also in operation for the convenience of large consumers, ensuring products and inventory at their doorstep.

IndianOil's ISO-9002 certified Aviation Service commands an enviable 63% market share in aviation fuel business, successfully servicing the demands of domestic and international flag carriers, private airlines and the Indian Defence Services. The Corporation also enjoys a 65% share of the bulk consumer, industrial, agricultural and marine sectors.

With a steady aim of maintaining its position as a market leader and providing the best quality products and services, IndianOil is currently investing Rs. 47,000 crore in a host of projects for augmentation of refining and pipelines capacities, expansion of marketing infrastructure and product quality upgradation.

Innovation is key

IndianOil has a sprawling world-class R&D Centre that is perhaps Asia's finest. It conducts pioneering work in lubricants formulation, refinery processes, pipeline transportation and alternative fuels, and is also the nodal agency of the Indian hydrocarbon sector for ushering in Hydrogen fuel economy in the country. The Centre holds 212 active patents, with over 100 international patents.

Some of the in-house technologies and catalysts developed by IndianOil include the INDMAX technology (for maximising LPGas yield), OilivorousS bio-remediation technology (extended to marine applications too), Diesel Hydro DeSulphurisation (DHDS) catalyst, a special Indicat catalyst for Bharat Stage-IV compliant Diesel, IndVi catalyst for improved distillate yield and FCC throughput, and adsorbent based deep desulphurisation process for gasoline and diesel streams Redefining the horizon

Fig. 1.6 : Refining

In Petrochemicals, IndianOil offers a full slate of products including Linear Alkyl Benzene (LAB), Purified Terephthallic Acid (PTA) and an extensive range of polymers. IndianOil holds a significant market share of LAB in India and exports to 19 countries. It is also one of the largest suppliers of Mono-Ethylene Glycol (MEG) in the domestic market clocking a sales volume of 151 TMT during 2010-11. Execution of a state-of-the-art 120,000 tonnes per annum Styrene Butadiene Rubber (SBR) unit is underway at Panipat. The SBR unit is expected to further strengthen IndianOils presence in the speciality petrochemicals sector.

Fig. 1.7 Refinery Night Vision

In Exploration & Production, IndianOil's domestic portfolio includes 11 oil and gas blocks and 2 CBM blocks in India including 2 blocks as part of a consortium under NELP-VIII (blocks GK-OSN-2009/1 and GK-OSN-2009/2). The overseas portfolio includes ten blocks spread across Libya, Iran, Gabon, Nigeria, Timor-Leste and Yemen. Exploration activities are at various stages of progress. In addition, as part of consortium, IndianOil has been awarded Project -1 in the Carabobo heavy oil region of Venezuela. To boost E&P activities, IndianOil has incorporated Ind-OIL Overseas Ltd. a special purpose vehicle for acquisition of overseas E&P assets in partnership with Oil India Ltd.

Fig. 1.8 : Project-1

Natural Gas marketing is another thrust area for IndianOil with special focus on City Gas Distribution (CGD) business. The Corporation has entered into franchise agreements with several CGD players to market Compressed Natural Gas through its retail outlets. During 2010-11, gas sales grew by an impressive 20.7% to 2.3 million tones from 1.91 million tones in the previous year.

IndianOil's joint venture with GAIL India Ltd. - Green Gas Ltd. is authorised to take up city gas distribution in Agra. A long term gas supply agreement has been signed with NTPC. IndianOil is setting up a 5 MMTPA LNG import, storage & regassification terminal at Ennore (outskirts of Chennai). This LNG Terminal would be first of its kind on the East Coast of India.

Furthermore, in consortium with GSPC, HPCL and BPCL, IndianOil won gas pipeline bids for Mallavaram to Bhilwara and Vijaypur via Bhopal Mehsana to Bhatinda and Bhatinda to Jammu and Srinagar.

ABOUT BARAUNI REFINERYIOCL is one of the largest public sector organization in india.The BARAUNI refinery is one of the refinery run under IOCL. The BARAUNI refinery situated in the oil town of BARAUNI in Assam is the oldest refinery in Asia. The credit for setting up of this refinery goes to the British officers serving in Assam,who found traces of oil in river water in1828.However the oil well could be developed only at Naharpong, Assam. On 19th october, 1899,oil was made to struck successfully at the depth in BARAUNI.In 1901,the refinery was comissioned.It was initially under the control of British and was taken over by the Burmah Oil Company.Later on, this came under Assam Oil Division. The refinery with an installed capacity of 0.5 MMTPA has been running ever since 1923 with old and absolute technology.It was nationalized in 1981and the planned modernization programme is embarked on. Since then the refinery has undergone a lot of changes. Some of the older plants have been placed by modern technology. This enhanced the capacity of the refinery to 0.65 MMTPA.

The main units of refinery are CDU (Crude Distillation Unit) and one DCU (Delayed Cocking unit) and coke calcinations unit AVU(Atmospheric vacuum unit),ETP(Effluent Treatment plant),LDU(LPG Dispatch unit) etc. The products of the refinery are- Naphtha, LPG, Motor Sprit., aviation turbine fuel (ATF), superior kerosene oil (SKO), High speed diesel oil (HSD), Light Diesel oil (LDO) and petroleum cokes. It is the first refinery to produce Lead free motor sprit.

The units in the petroleum sectors are- xylene plant, dimethyle terepthalate plant and fiber plant.

CRUDE OIL DISTILLATION OIL

INTRODUCTION

The Crude Distillation Unit of Barauni Refinery was commissioned in January 1962 with a refinery capacity of 0.75MMTPA. The capacity increased to 0.85 MMTPA after a major revamp in 1986. The capacity has been further increased to 1.15MMTPA after carrying out few process debottle necking and desalter commissioning. Another major revamp took place in August 2000 to increase the refinery capacity to the present 1.3 MMTPA of Bihar mix crude.

The unit receives crude oil from Oil India Ltd. And ONGC and distillate it to the following products,

1. Fuel gas

-Fuel for heaters

2. Light Gasoline

-Feed stock for LPG & NSF / Isosiv

3. Heavy Gasoline

- Feed stock for NSF

4. SR Kero- I/II

-Feed stock for Hydrotreater

5. SR Gas Oil

- Feed stock for Hydrotreater

6. RCO

-Feed stock for DCU

Feed through put

NORMAL: 3360 TONNES PER DAY

FREQUENCY OF SHUTDOWN

DESIGN RUN LENGTH: 2 YEARS.

PRESENT RUN LENGTH: 4 YEARS

PROCESS FLOW SYSTEM

Preheat Train before Desalter

The crude from battery limit is pumped by pump P-1/1A at about 15.8 Kg/Cm2g through a preheat train where it is heated by, prefactionator overhead vapors , RCO , SR Kero-II, SR Gas Oil , SR kero-II and RCO to a temperature of 130(C before entering the desalter .

Desalter V-101

In the desalter, wash water and crude are mixed. In the presence of an electric field, the salt in crude dissolves in water, which is then separated from the oil. The effluent water preheats the incoming wash water in E-101 before being sent to desalter wash water vessel. The desalter pressure is maintained at about 13.0 to 15.0 Kg/cm2g.Pretopping Column (CL-1)

The purpose of this column is to remove the SR light gasoline (IBP to 110(C cut point on TBP) from overhead and reduce the load on the crude column CL-2.

Preheat train at CL-1 bottoms

The topped crude from CL-1 bottoms is pumped by pumps P-2/2A to exchangers S-16/S-9D in series, where it is heated by SR Gas Oil Circulating Reflux (SRGO CR). It then passes to S-21 where it is heated by Reduced Crude Oil (RCO) to about 245.9(C. At this temperature pre topped crude enters Atmospheric furnace (C-1A). CL-1 bottom level is maintained by LIC-003, which operates LV-1334 located on the feed line to CL-1. FI-1137 provided on P-2/2A discharge line provides the flow rate of pretopped crude.

Atmospheric Furnace (C-1A

The purpose of the Atmospheric furnace is to provide the heat of vaporization of hydrocarbons lighter than RCO in the pretopped crude for fractionation in column CL-2.

AIRPREHEATING SYSTEMThe purpose of this system is to recover heat from hot flue gas so as to increase the efficiency of the furnace to about 90%. Hot flue gases exiting convection section of heater are routed to top of air pre heater and flown downwards preheating the air and improving the thermal efficiency of heater.

The air preheater consists of 2 sections:

A. Cast APH

B. Glass APH

Main fractionating cloumn CL-2:-The purpose of this column is to separate the preflashed crude into saleable products by distillation.

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