Indian Oil Corporation Ltd.

Resid Upgradation Project Gujarat Refinery VGO Unionfining Process Unit

Vacuum gas oil (VGO) Unionfining process is typically designed to either upgrade the feed quality for further processing or improve VGO quality so that it could be used as an environmentally friendly fuel oil. This unit is designed to process a blend of vacuum gas oil from Vacuum unit (straight run feed component) and vacuum gas oil from Co er unit. There is a possibility of processing up to !"# of the unit capacity of straight run feed component from gas blan eted storage. The intent is to process all produced co er vacuum gas oil $hile maintaining adequate ratio of straight run vacuum gas oil to co er vacuum gas oil. The capacity of this unit is about %.& ''T(). The design cases $ere identified as Case * and Case ** (both +tart of ,un and -nd of ,un). The unit is designed to be able to process up to !"# of the cold feed (." /C) from gas blan eted storage. 0hen there is a need for processing of such amount of cold feed1 it is e2pected that the unit $ill operate at turndo$n mode. Reactor Section 3resh feed from co er and vacuum unit passes through bac $ash filter (%"456G6"&) and then enters the gas blan eted feed surge drum (%"456V6"&) operating at a pressure of 5.! g7cm%(g). The charge pump (%"456(6"&)78) $ith a discharge pressure of &"4 g7cm%(g) ta es the suction from the feed surge drum and pumps the oil to the reactor via the tube side of hot separator vapour feed e2changer (%"456-6"9) and effluent feed e2changer (%"456-6"%). ,ecycle gas heated to around 9%: "C in the recycle gas heater (%"45636"&) is mi2ed $ith the gas oil upstream of the reactor (%"456,6"&). The combined feed stream enters the top of the reactor at a temperature of around 5.! "C. The reactor is divided into individual catalyst beds and cold recycle gas at about (9"6:! "C) is brought into the reactor at the interbed quench points in order to cool the reactants and control the reaction rate. The reactor effluent passes through the shell side of effluent6recycle gas hot e2changer (%"456-6"&) 1 effluent feed e2changer (%"456-6"%) and effluent recycle gas cold e2changer (%"456-6"5) to recover heat of reaction and then enters the hot separator (%"456V6"%) operating at a pressure of .9 g7cm%(g). ;ot separator is installed for liquid 7 vapour separation. ;eavier hydrocarbon material from the reactor effluent is sent to the hot flash drum (%"456V6"5) operating at a pressure of 55 g7cm%(g) and then to the stripper (%"456C6"%). The overhead vapour from the hot separator flo$s through the shell side of hot separator vapour feed e2changer (%"456-6"9)1 hot separator vapour recycle gas e2changer (%"456 -6"!) and hot separator vapour condenser (%"456-)6"%) into the cold separator (%"456V6"9) $hich is operating at a pressure of .& g7cm%(g). +ulphur and nitrogen contained in the feed are converted to ;%+ and <;5 in the reactor. ;ence $ash $ater is in=ected upstream of %"456-)6"% to prevent deposition ammonium salts that can corrode and foul the cooler. The flashed vapour from the hot flash drum is cooled in the hot flash vapour condenser (%"456-)6"&) and then sent to cold flash drum (%"456 V6"!) operating at a pressure of 5% g7cm%(g).>iquid hydrocarbon from the cold separator flo$s via cold flash drum 1 tube side of diesel pump around stripper feed e2changer (%"456-6&!)1 shell side of product fractionator bottom stripper feed e2changer (%"456-6&%) into the stripper (%"456C6"%). The flashed vapour from the cold separator is sent to the recycle gas scrubber (%"456C6"&) operating at a pressure of .& g7cm%(g) via recycle gas cooler (%"456-6"?). The flashed vapour from the cold flash drum is routed to the off gas noc out drum (%"456V6":) via off gas cooler (%"456-6":). Condensables are routed to the liquid hydrocarbon stream leaving the cold flash drum and non condensables are routed to '( Off gas scrubber. 0ater is collected in a boot attached to the cold separator and is removed on level control and sent to $aste $ater stripping unit. The recycle gas from the cold separator enters the scrubber (%"456C6"&) from the bottom via recycle gas noc out drum (%"456V6"?) and is contacted counter current $ith amine to remove ;%+ from the gas stream. ;%+ reduces the partial pressure and suppresses catalyst activity hence its removal becomes essential. The scrubbed gas leaves from the top of the scrubber and is sent to the recycle gas compressor (%"456@6"&). 'a e up hydrogen is fed from the hydrogen plant at a pressure of &4.. g7cm%(g). This hydrogen is added upstream of the recycle gas compressor hence the pressure needs to be boosted up to .& g7cm%(g). *n order to achieve this pressure a % stage ma e up gas compressor (%"456@6"%)78) is added.

Indian Oil Corporation Ltd. Resid Upgradation Project Gujarat Refinery VGO Unionfining Process Unit
Fractionation Section ;ot flash drum and cold flash drum liquids go to a stripping column (%"456C6"%) $hich operates at a pressure of around . g7cm%(g). The purpose of stripper is to remove ;%+ for trouble free operation. +team is used to strip naphtha and lighter material in the stripper. The vapours leaving the stripper are condensed in stripper condenser (%"456-)6"9)1 stripper trim condenser (%"456-6&") and flo$ into the overhead stripper receiver (%"456V6&&). The stripper receiver separates the non condensable vapour heavily loaded $ith ;%+1 hydrocarbon liquid and sour $ater. Overhead liquid is reflu2ed to the stripper and the balance amount is routed to the debutaniAer (%"456C6":) to tray no %" operating at a pressure of &&.95 g7cm%(g). The overhead vapour from the debutaniAer is routed to debutaniAer receiver (%"456 V6&!) $here non condensable vapour loaded $ith ;%+ is separated from liquid hydrocarbon. Overhead liquid is reflu2ed to the debutaniAer. +tripping vapour is provided by thermosiphon reboiler (%"456-6%5) and light naphtha product is removed from bottom of the debutaniAer. The overhead vapour from the stripper receiver and debutaniAer receiver is routed to the >( Off gas scrubber. +tripper bottoms liquid is pumped out and heated first in the product fractionator feed bottoms e2changer (%"456-6&&) and then heated to 5.! Beg Cel in product fractionator feed heater (%"45636"%) and then sent to product fractionator (%"456C6"5) on tray no &" $hich has the operating pressure of &.95 g7cm%(g). >( stripping steam is added to the bottom section of the product fractionator to assist $ith the removal of light hydrocarbons from the bottom product. The overhead vapour from the product fractionator is routed to the product fractionator receiver (%"456V6&9) via product fractionator condenser (%"456-)6"?). The liquid hydrocarbon is pumped out to naphtha storage. ) fuel gas push pull pressure control system is provided to maintain receiver pressure of ".? g7cm%(g). Biesel (roduct is $ithdra$n from total accumulator tray belo$ tray no %? of the product fractionator and is routed to diesel stripper (%"456C6"!) $here steam is used to provide stripping vapour. Biesel product is removed from the bottom and cooled in '( steam generator (%"456-6&:)1 product cooler (%"456-)6 "!) and trim cooler (%"456-6&?). 'ost of the $ater is removed in diesel coalescer (%"456'6"5) and diesel product is sent to storage via salt drier (%"456V6&%). @erosene product is $ithdra$n from total accumulator belo$ tray no 9". of the product fractionator .@erosene is then routed to the erosene stripper (%"456C6"9) $here thermosiphon reboiler (%"456-6&.) is used to provide the stripping vapour. @erosene product is then cooled in product cooler (%"456-)6":)1 trim cooler (%"456-6&4) and then sent to storage. Besulphurised vacuum gas oil product is $ithdra$n from the bottom of the product fractionator and cooled in a series of e2changers including %"456-6&&1 %"456-6&%1 %"456-6&. 1 %"456-6%51 %"456-6&51 %"456-6%" 1 %"456-6%: and then routed to 3CC Unit. Off Gas Scrubbing Section >( and '( off gas scrubber use amine to absorb most of the hydrogen sulphide in the off gas stream. ,emoval of the hydrogen sulfide in the Off Gas +crubbers increases the hydrogen partial pressure in the off gas before it is being sent to the hydrogen recovery. >ean amine from the >ean )mine (ump discharge is sent to the top tray of the Off Gas +crubbers.