IOCL Vocational Training Report

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    Submitted by:

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    Acknowledgement Indian Oil History

    Barauni Refinery: Introduction

    Present Configuration

    Basic Refinery Processes

    Primary Processing Units

    Atmospheric Distillation Unit

    Vacuum Distillation Unit

    Coker Unit

    Catalytic Reforming Unit (CRU)

    BXP Unit(RFCCU, DHDT, SRU, HGU)

    Prime G+

    (NHDT, ISOM, SHU) Some Units IN Detail with PFD

    Typical product pattern

    Safety measures in Refinery

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    ACKNOWLEDGEMENT

    It’s a great for being a part of IOCL which is the world’s 98 th largestpublic corporation according to the FORTUNE GLOBAL’s 500 list andamongst the top companies of India by FORTUNE INDIA 500 IN 2011.

    This acknowldgement is a way by which I am getting the opportunityto show the deep semse of gratitude and obligation to all thepeople who have prov ided me with inspiration and guidance duringthe preparation of the training report.

    I would take this chance to thank Mrs.Krishna Kumari, Officer T&D ,Mr. Kalyan Bagchi DM (T&D) ,Ms Nilu Rani (O.A, T&D) for prov iding uswith this wonderful opportunity to interact with the experts in Baraunirefinery. I would also like to express my sincere gratitude towards Mr.C.V.Ingle, Production Manager for mentoring us throughout thetraining period and all the learned employees who took pains toquench my curiosity and shared their knowledge.

    Last but not the least; I would like to thank my parents whoseencouragement and motivation was a constant source of strengthand without which it wouldn’t have been possible.

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    INDIAN OIL HISTORY

    Indian Oil, the largest commercial enterprise of India (by salesturn over), is India’s sole representative in Fortune's prestigious listingof the world's 500 largest corporations, ranked 189 for the year 2004.It is also the 17th largest petroleum company in the world. Indian Oilhas a sales turnov er of 1, 20,000 crores and profits of 8,000 crores.Indian Oil has been adjudged second in petroleum trading amongthe 15 national oil companies in the Asia-Pacific region. As thepremier National Oil Company, Indian Oil’s endeavor is to serve thenational economy and the people of India and fulfill its vision ofbecoming an integrated, diversified, and transnational energymajor.Beginning in 1959 as Indian Oil Company Ltd, Indian Oil CorporationLtd. was formed in 1964 with the merger of Indian Refineries Ltd.(Est.1958). As India's flagship national oil company, Indian Oilaccounts for 56% petroleum products market share, 42% nationalrefining capacity and 67% downstream pipeline throughputcapacity. IOCL touches every Indian’s heart by keeping the vital oilsupply line operating relentlessly in ev ery nook and corner of India. Ithas the backing of over 33% of the country’s refining capacityas on 1 st April 2002 and 6523 km of crude/product pipelines acrossthe length and breadth of the country. IOCL’s vast distributionnetwork of over 20000 sales points ensures that essential petroleumproducts reach the customer at the right place and at the right time.Indian Oil controls 10 of India's 18 refineries - at Digboi, Guwahati,Barauni, Koyali, Haldia, Mathura, Panipat, Chennai, Narimanam &Bongaigaon with a current combined rated capacity of 49.30 millionmetric tonnes per annum (MMTPA) or 990 thousand barrels per day(bpd). Indian Oil’s world -class R&D Centre has won recognition for itspioneering work in lubricants formulation, refinery processes, pipelinetransportation, and bio-fuels. It has developed over 2,100formulations of SERVO brand lubricants and greases for v irtually all

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    conceivable applications - automotive, railroad, industrial andmarine – meeting stringent international standards and bearing thestamp of approval of all major original equipment manufacturers.The centre has to its credit ov er 90 national and international

    patents. The wide range of brand lubricants, greases, coolants, andbrake fluids meet stringent international standards and bear thestamp of approv al of all major original equipment manufacturers.Indian Oil operates 17 training centres throughout India for up-skilling, re-skilling, and multi-skilling of employees in pursuitof corporate excellence. Among these, the foremost learningcentres are Indian Oil Institute of Petroleum Management atGurgaon, Indian Oil Management Centre for Learning at Mumbai,and Indian Oil Management Academy at Haldia, hav e emerged as

    world-class training and management academies. Indian Oil Instituteof Petroleum Management, the Corporat ion's apex center oflearning, conducts advanced management developmentprograms in collaboration with reputed institutes. It also offers aunique mid-career International MBA programs in PetroleumManagement. Indian Oil aims at maintaining its leadership in theIndian hydrocarbon sector by continuous assimilation of emergingInformation Technology and web-enabled solutionsfor integrat ing and opt imizing the Corporation's hydrocarbon

    value chain. It is has implemented an IT re-engineering project titledManthan, which includes an Enterprise Resource planning (ERP)package which will standardize and integrate the Corporation'sbusiness on a common IT platform through a robust hybrid wide areanetwork with appropriate hardware.

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    Barauni Refinery, the second Public Sector Oil refinery of thecountry, was built in collaboration with the erstwhile USSR &limited Romanian participation.

    Inaugurated on 15 th Jan’65 by the then Hon’ble minister forPetroleum & Chemicals, Prof. Humayun Kabir

    Located at a distance of approximately 120 km from Patna,

    Bihar.

    Facilities

    • 16 nos. of Process Plants

    • Offsite facilities including:

    Storage tanks

    Effluent Treatment Plant & Bio Treatment Plant Product dispatch facilities, including 3 nos. of gantries

    • Captive Power Plant with:

    6 Boilers : 5 X 75MT/hr+1X150MT/hr

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    4 TG’s : 1x 5.5 MW + 1X 12 MW + 1 X 12.5 MW +1 X 20 MW

    2 Gas Turbines : 2X 20MW with HRSG (48MT/ hr)

    Present Configuration

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    Vac. Distillation: Distillation of crude in vacuum toav oid thermal cracking at higher operatingtemperatures.

    Atmospheric Distillation Unit

    Crude oil is sent to the atmospheric distillation unit after desaltingand heating. The purpose of atmospheric distillation is primary

    separation of various 'cuts' of hydrocarbons namely, fuel gases, LPG, naptha, kerosene, diesel and fuel oil. The heavy hydrocarbonresidue left at the bottom of the atmospheric distillation column issent to v acuum distillation column for further separation ofhydrocarbons under reduced pressure.As the name suggests, the pressure profile in atmospheric distillationunit is close to the atmospheric pressure with highest pressure at thebottom stage which gradually drops down till the top stage of thecolumn.

    The temperature is highest at the bottom of the column which isconstantly fed with heat from bottoms reboiler. The reboiler v aporizespart of the bottom outlet from the column and this vapor is recycledback to the distillation column and trav els to the top stageabsorbing lighter hydrocarbons from the counter current crude oilflow. The temperature at the top of the column is the lowest as theheat at this stage of the column is absorbed by a condenser whichcondenses a fraction of the vapors from column overhead. The

    condensed hydrocarbon liquid is recycled back to the column. Thiscondensed liquid flows down through the series of column trays,flowing counter current to the hot v apors coming from bottom andcondensing some of those vapors along the way.

    Thus a reboiler at the bottom and a condenser at the top along witha number of trays in between help to create temperature and

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    pressure gradients along the stages of the column. The gradualvariation of temperature and pressure from one stage to anotherand considerable residence time for vapors and liquid at a tray helpto create near equilibrium conditions at each tray.

    The heaviest hydrocarbons are taken out as liquid flow from thepartial reboiler at bottom and the lightest hydrocarbons are takenout from the partial condenser at the column overhead. For the inbetween trays or stages, the hydrocarbons become lighter as onemov es up along the height of the column. Various other cuts ofhydrocarbons are taken out as sidedraws from different stages of thecolumn. Starting from LPG at the top stages, naptha, kerosene, dieseland gas oil cuts are taken out as we mov e down the stages of

    atmospheric column.

    Vacuum Distillation Unit

    Crude oil is first refined in an Atmospheric Distillation Column.Fractions of crude oil such as lighter gases (C1-C4), gasoline,naphtha, kerosene, fuel oil, diesel etc. are separated in theatmospheric distillation column. The after taking out these lighterhydrocarbon cuts, heavy residue remaining at the bottom of theatmospheric distillation column needs to be refined. These heav yhydrocarbon residues are sent to a Vacuum Distillation Column forfurther separation of hydrocarbons under reduced pressure.

    Heav ies from the atmospheric distillation column are heated toapproximately 400˚C in a fired heater and fed to the vacuumdistillation column where they are fractionated into light gas oil,heavy gas oil and vacuum reside. Some heav y hydrocarbonscannot be boiled at the operating temperature and pressureconditions in the atmospheric distillation column. Hence they exit thebottom of the column in liquid state and are sent to the v acuumdistillation column where they can be boiled at a lower temperature

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    when pressure is significantly reduced. Absolute operating pressure ina Vacuum Tower can be reduced to 20 mm of Hg or less(atmospheric pressure is 760 mm Hg). In addition, superheatedsteam is injected with the feed and in the tower bottom to reduce

    hydrocarbon partial pressure to 10 mm of mercury or less. Lowerpartial pressure of the hydrocarbons makes it even more easier forthem to be vaporized, thus consuming less heat energy for theprocess.

    Two different cuts of hydrocarbons - 'light vacuum gas oil' and'heav y v acuum gas oil' are separated in the v acuum distillationcolumn at different stages of the column, based on the differencebetween their boiling point ranges. The liquid being drawn at low

    pressure needs to be pumped. Then it is heated and partiallyrecycled back to the column. Part of it is taken out as v acuumdistillation products - 'light v acuum gas oil' or 'heavy v acuum gas oil'.Light v acuum gas Oil is sent to a hydrotreater and then to a'catalytic cracking' unit to obtain smaller chain hydrocarbons. Heav yvacuum gas oil is also sent for cracking using hydrogen in a'hydrocracking unit' to produce smaller chain hydrocarbons.

    Heavy hydrocarbons which cannot be boiled even under reduced

    pressure remain at the bottom of the column and are pumped outas 'vacuum residue'. The vacuum distillation column bottom residuecan only be used for producing coke in a 'coker unit' or to producebitumen.

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    Coker UnitCoking is a refinery unit operation that upgrades material called

    bottoms from the atmospheric or v acuum distillation column intohigher-value products and, as the name implies,produces petroleum coke — a coal-like material.Petroleum coke has uses in the electric power and industrial sectors,as fuel inputs or a manufacturing raw material used to produceelectrodes for the steel and aluminum industries. In 2011 , the refiningindustry supplied 132 million barrels of petroleum coke with most of itsubsequently consumed as fuel.Two types of coking processes exist — delayed coking and fluid

    coking. Both are physical processes that occur at pressures slightlyhigher than atmospheric and at temperatures greater than 900 o Fthat thermally crack the feedstock into products such as naphthaand distillate, leaving behind petroleum coke. Depending on thecoking operation temperatures and length of coking times,petroleum coke is either sold as fuel-grade petroleum coke orundergoes an additional heating or calcining process to produceanode-grade petroleum coke.With delayed coking, two or more large reactors, called coke drums,

    are used to hold, or delay, the heated feedstock while the crackingtakes place. Coke is deposited in the coke drum as a solid. This solidcoke builds up in the coke drum and is remov ed by hydraulicallycutting the coke using water. In order to facilitate the remov al of thecoke, the hot feed is diverted from one coke drum to another,alternating the drums between coke removal and the cracking partof the process. With fluid coking, the feed is charged to a heatedreactor, the cracking takes place, and the formed coke istransferred to a heater as a fluidized solid where some of it is burned

    to provide the heat necessary for the cracking process. Theremaining coke is collected to be sold.Like other secondary processing units, coking can play an importantrole in refinery economics depending on the type and cost of thecrude oil run at a refinery. As the quality of crude oil inputs to arefinery declines, coupled with greater demands for transportation

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    fuels, coking operations will serv e to meet transportation fueldemands and also produce increasing quantities of fuel-grade andanode-grade or needle petroleum coke.

    Catalytic Reforming Unit (CRU)

    Catalytic reforming is a major conv ersion process in petroleumrefinery and petrochemical industries. The reforming process is a

    catalytic process which converts low octane naphthas into higheroctane reformate products for gasoline blending and aromatic richreformate for aromatic production. Basically, the process re-arrangesor re-structures the hydrocarbon molecules in thenaphtha feedstocks as well as breaking some of the molecules intosmaller molecules. Naphtha feeds to catalytic reforming includeheavy straight run naphtha. It transforms low octane naphtha intohigh-octane motor gasoline blending stock and aromatics rich inbenzene, toluene, and xylene with hydrogen and liquefied

    petroleum gas as a byproduct. With the fast growing demandin aromatics and demand of high - octane numbers, catalyticreforming is likely to remain one of the most important unit processesin the petroleum and petrochemical industry.Basic steps in catalytic reforming involve1) Feed preparation: Naphtha Hydrotreatment2) Preheating: Temperature Control,3) Catalytic Reforming and Catalyst Circulation and Regeneration incase of continuous reforming process

    4) Product separation: Remov al of gases and Reformate byfractional Distillation5) Separation of aromatics in case of Aromatic productionREACTIONS IN CATALYTIC REFORMINGFollowing are the most prev alent main reactions in catalyticreforming

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    DesirableDehydrogenation of naphthenes to aromaticsIsomerisation of paraffins and naphthenesDehydrocyclisation of paraffins to aromatics

    Non-DesirableHydrocracking of paraffins to lower molecular weight compoundsDehydrogenation & Dehydrocyclization: Highly endothermic, causedecrease intemperatures, highest reaction rates, aromatics formed hav e highB.P so end point of gasolinerisesDehydrogenation reactions are very fast, about one order ofmagnitude faster than the other

    reactions. The reaction is promoted by the metallic function ofcatalystMethyl cyclohexane Toluene + H2MCP Benzene + H2Dehydrocyclisation: It inv olv es a dehydrogenation with a release ofone hydrogen molefollowed by a molecular rearrangement to form a naphthene andthe subsequent dehydrogenation of the naphthene. i-paraffins toaromaticsof paraffins

    n-heptane , toluene + H2Favourable Conditions: High temperature, Low pressure, Low spacevelocity, Low H2/HC ratioIsomerisation: Branched isomers increase octane rating, Small heateffect, Fairly rapid reactions.Favourable Conditions: High temperature, Low pressure, Low spacevelocity, H2/HC ratio no significant effectNaphthenes dehydro-Isomerisation: A ring re-arrangement reaction,Formed alkyl- cyclohexane dehydrogenate to aromatics.• Octaneincrease is significant, Reaction is slightly exothermic

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    BXP Units

    RFCCU

    A Residue FCC (RFCC) unit expands the versatility and profitability ofan FCC to crack a wider variety of feedstock:

    Traditional FCC feedstocks

    Deeply Deasphalted Oil Atmospheric Residue Vacuum Residue

    The quality of the feed is the main determinant of the yields andproduct properties. The yield of v aluable gasoline and LPG productsin the FCC unit will be mainly influenced by the hydrogen content ofthe feed. Feed contaminants such as sulfur, nitrogen, ConradsonCarbon Residue (ConC) and metals also impact the yield and/or

    product quality. As a result it is often adv antageous to either partiallyor fully hydrotreat the feedstock to improv e the hydrogen contentand reduce the lev el of contaminants.When processing residues containing high levels of metals (Ni, V andNa) and ConC v alues of 3-10 wt%, more sophisticated FCC designsare required. The reaction section will be designed to inject andefficiently crack heavier molecules. The regenerator section is

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    designed to burn more coke, minimize catalyst deactivation in thepresence of high metals loading on the catalyst, and control theheat balance by using a two-stage regenerator design ( R2R).For expanded product flexibility, the RFCC unit can be integrated

    with upstream units such as resid hydrotreating/ hydrocracking tobalance the gasoline and distillate products, or downstream unitssuch as Polynaphtha (FlexEne™ c oncept) in order to offer higherflexibility toward targeted products (Gasoline, Diesel or Propylene).

    Diesel Hydrotreating Unit (DHDT)

    Objective : To meet the Euro – III/IV diesel quality requirement (350/50 ppm‘S’and Min. 51 Cetane No.)

    Feed : Straight run diesel / FCC diesel component/ Coker andVisbreakerdiesel components.

    Catalyst : Ni-Mo oxides Chemical reactions : Desulphurisation and Denitrification

    In Dieselhydrodesulfurization / hydrotreating process, diesel feed ismixed with recycle Hydrogen ov er a catalyst bed in a trickle bedreactor at temperature of 290-400°C and pressure of 35-125 bar. Themain chemical reactions in DHDS/DHDTarehydrodesulphurization(HDS), hydrodenitrification (HDN), andaromatic and olefin saturation. These reactions are carried on bi-functional catalysts. Reactor effluent is separated into gas and liquidin a separator. Gas is recycled back to the reactor after amine washalong with make-up Hydrogen and liquid is sent to the stripper forremov al of light gases and H2S.

    Advantages : Indigenous Process design& technology

    • Capable of producing ultra low Sulfur meeting BS-IV dieselspecifications

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    • Proprietary Reactor internals. • Competitive with foreignlicensors

    • Proprietary DHDS/DHDT catalyst system so as to offer acomplete package.

    Design and Engineering experiences of EIL

    Sulphur Recovery Unit SRU)

    Sulphur removal facilities are located at the majority of oil and gasprocessing facilities throughout the world. The sulphur recovery unitdoes not make a profit for the operator but it is an essentialprocessing step to allow the overall facility to operate as thedischarge of sulphur compounds to the atmosphere is severelyrestricted by env ironmental regulations.The basic Claus unit comprises a thermal stage and two or threecatalytic stages.

    Typical sulphur recov eries efficiencies are in the range 95-98%depending uponthe feed gas composition and plant configurationH2S + 1½O2 > SO2 + H2O (1)2H2S + O2 3/x Sx + 2 H2O (2)Some of the H2S in the feed gas is thermally converted to SO2 in thereaction furnace of the thermal stage according to reaction (1). Theremaining H2S is then reacted with the thermally produced SO2 toform elemental sulphur in the thermal stage and the subsequent

    catalytic stages according to reaction (2). Claus reaction (2) isthermodynamically limited and has a relatively low equilibriumconstant for reaction (2) over the catalytic operation region.As the feed acid gas normally contains other compounds, whichcould include carbon dioxide, hydrocarbons, mercaptans andammonia, the actual chemistry in the furnace is very complex.

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    The hot combustion products from the furnace at 1000- 1300°Center the

    waste heat boiler and are partially cooled by generatingsteam. Any steam lev el from 3 to 45 bar g can be generated.

    The combustion products are further cooled in the first sulphurcondenser,usually by generating LP steam at 3 – 5 bar g. This cools the gasenough to condense the sulphur formed in the furnace, which isseparated from the gas and drained to a collection pit.

    In order to avoid sulphur condensing in the downstreamcatalyst bed, the gas leav ing the sulphur condenser must beheated before entering the reactor.

    The heated stream enters the first reactor, containing a bed of

    sulphur conversion catalyst. About 70% of the remaining H2Sand SO2 in the gas will react to form sulphur, which leaves thereactor with the gas as sulphur v apour.

    The hot gas leav ing the first reactor is cooled in the secondsulphur condenser, where LP steam is again produced and thesulphur formed in the reactor is condensed.

    A further one or two more heating, reaction, and condensingstages follow to react most of the remaining H2S and SO2.

    The sulphur plant tail gas is routed either to a Tail Gas treatment

    Unit for further processing, or to a Thermal Oxidiser to incinerateall of the sulphur compounds in the tail gas to SO2 beforedispersing the effluent to the atmosphere

    MSQ UNITIt consists of:

    1. PRIME G+2. NHDT3. ISOM

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    Prime G+The Prime-G+ process relies on unrivalled expertise to prov ide themost appropriate catalytic solution based on simple and robustdesigns that can achieve the following targets: Very high desulfurization rate with good octane retention

    Excellent gasoline yield retention without RVP increase (nocracking reactions)

    Minimum hydrogen consumption

    High operational reliability through a tailor-made conventionalhydrotreatment

    Low capital cost investment through a simple fixed bedtechnology

    High catalyst cycle length that keeps the unit running 100% of theFCC turnaround

    Fully regenerable catalysts (in-situ or ex-situ) at low contaminantlev els

    Ability to co-process other sulfur-rich streams such as light coker,

    v isbreaker, straight run or steam cracker naphthas Ability to retrofit existing assets

    Axens Prime-G+ offer is particularly flexible allowing different processconfigurations (schemes with or withoutsplitter, 1 st stage or 2 nd stage selective HDS unit) to best fit thegasoline pool requirement and also maximize refinery profitability.

    Although the naphtha splitter may be optional depending on the

    required HDS sev erity, the preferred arrangement for minimization ofoctane loss is a scheme with the association of a Prime-G+ selectivehydrogenation unit (SHU) and a splitter , the so called the "Prime-G+1st Step" for light naphtha desulfurization and sweetening. It ideallycomplements the selective HDS on the heav ier fraction thatoutperforms all other processes.

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    All Prime G+ catalysts present a low sensitivity to impurities andexcellent stability suitable for the processing of cracked feedstockdue to their optimized metal content and highly neutral carrier.

    Specific grading materials developed by Axens are often installed atthe top of reactor catalytic beds in order to extend catalyst cyclelengths when processing highly reactiv e cracked feedstocks.

    Depending on the crude, FCC gasoline can contain arsenic which isa poison for all hydrotreatment catalysts. In the case of severecontamination, Axens can offer to install as part of the gradingmaterial a dedicated trapping mass which delivers v ery high arsenicretention without olefin saturation to preserv e the octane of the

    desulfurized FCC gasoline product.

    Selective Hydrogenation Unit

    SHU)

    Unsaturated LPG cuts from FCC and coker or Steam Cracking unitscontain unwanted dienes and/or acetylenes that need to beremov ed before further treatment.It’s used for upgrading unsaturated LPG cuts; by conv ertingbutadiene and MAPD, it greatly enhances the performance ofdownstream units.Here treatment of unsaturated LPG is required. Depending on thedownstream utilization of LPG cuts it can be used at low sev erity for selective butadiene/MAPD hydrogenation at higher severity to promote Hydroisomerization of 1-butene to 2-

    butene. Whatev er the application, special attention is paid during design tominimize losses of v aluable olefins.

    A series of catalysts is available to ensure high activ ity and optimumselectivity throughout the run cycle. It is important to make the

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    choice of catalyst in conjunction with the contaminants (e.g. sulfur)that are often present in cracked feedstock.This technology can be used to treat C 3, C 4 or combined C 3 andC 4 olefinic cuts.

    Naphtha Hydrotreatment UnitNHDT)

    Naphtha hydrotreatment is important steps in the catalytic reformingprocess for removal of the v arious catalyst poisons. It eliminates the

    impurities such as sulfur, nitrogen, halogens, oxygen, water, olefins, diolefins, arsenic and other metals presents in the naphtha feed stockto hav e longer life catalyst..* Sulphur: Mercaptans, disulphide, thiophenes and poison theplatinum catalyst. The sulphur content may be 500 ppm.*Maximum allowable sulphur content 0.5 ppm or less and watercontent

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    *Hydrogen partial pressure*H2/HC ratio, feed quality*Stripper bottom temperature

    Isomerization Unit (ISOM)

    Isomerization is a process in petroleum refining that conv erts n-butane, n-pentane and n-hexane into their respective isoparaffins ofsubstantially higher octane number. The straight-chain paraffins areconverted to their branched-chain counterparts whose componentatoms are the same but are arranged in a different geometricstructure. Isomerization is important for the conversion of n-butaneinto isobutane, to provide additional feedstock for alkylation units,and the conv ersion of normal pentanes and hexanes into higher

    branched isomers for gasoline blending. Isomerization is similarto catalytic reforming in that the hydrocarbon molecules arerearranged, but unlike catalytic reforming, isomerization just convertsnormal paraffins to isoparaffins.Butane isomerization produces feedstock for alkylation. Aluminumchloride catalyst plus hydrogen chloride are universally used for thelow-temperature processes. Platinum or another metal catalyst isused for the higher-temperature processes. In a typical low-temperature process, the feed to the isomerization plant is n-butaneor mixed butanes mixed with hydrogen (to inhibit olefin formation)and passed to the reactor at 230°-340° F and 200-300 psi. Hydrogenis flashed off in a high-pressure separator and the hydrogen chlorideremov ed in a stripper column. The resultant butane mixture is sent toa fractionator (deisobutanizer) to separate n-butane from theisobutane product.

    http://www.eoearth.org/article/Petroleum_refininghttp://www.eoearth.org/article/Catalytic_reforming_in_petroleum_refininghttp://www.eoearth.org/article/Hydrogenhttp://www.eoearth.org/article/Hydrogenhttp://www.eoearth.org/article/Catalytic_reforming_in_petroleum_refininghttp://www.eoearth.org/article/Petroleum_refining

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    Pentane/hexane isomerization increases the octane number of thelight gasoline components n-pentane and n-hexane, which arefound in abundance in straight-run gasoline. In a typicalC 5/C 6 isomerization process, dried and desulfurized feedstock is

    mixed with a small amount of organic chloride and recycledhydrogen, and then heated to reactor temperature. It is then passedover supported-metal catalyst in the first reactor where benzene andolefins are hydrogenated. The feed next goes to the isomerizationreactor where the paraffins are catalytically isomerized toisoparaffins. The reactor effluent is then cooled and subsequentlyseparated in the product separator into two streams: a liquidproduct (isomerate) and a recycle hydrogen-gas stream. The

    isomerate is washed (caustic and water), acid stripped, andstabilized before going to storage .

    http://www.eoearth.org/article/Hydrogenhttp://www.eoearth.org/article/Hydrogen

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    Some Refinery Units In DetailWith PFD’s and Explanation

    1. AVUs

    2. BXPs RFCCU DHDT HGU SRU

    3. CRU

    4. MSQ NHDT ISOM

    PRIME G+

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    Typical Product Pattern

    4.86% 3.97%

    15.29%

    13.1%

    48.65%

    2.23%

    0.821.12

    0.80%

    0.20%

    LPG SRN MS SKO HSDRPC Bitumen FO CBFS Sulphur

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    Safety Measures in Refinery

    Process interlocks Work permit systems Personal Protective Equipment (PPE) Special height and fire permit Gas detector Safety training

    Standing instructions Firefighting equipments Material Safety Data Sheet (MSDS) Safety relief systems

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