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SUBMITTED BY:
USAMA SHAKIL
SERVICE # 361556
Student, B.Sc. Chemical Engineering
University of Engineering & Technology, Lahore
DEPARTMENT OF OPERATIONS
ACKNOWLEDGEMENT
The preparation and writing of this report faced many challenges, as I have tried to
cover complete Heavy Crude Unit in this report. The report could not have been
researched, compiled and written in these circumstances without the assistance of
HCU Plant Staff and Manager.
I am highly indebted to Engr. Arshad Nazir (Manager Operations) and also my
seniors Engr. Daniyal (Trainee Engineer), Engr. Ali Hudaib (Trainee Engineer)
and Engr. Salmaan Javaid (Trainee Engineer) for
CONTENTS
INTRODUCTION..........................................................................................................................1
HISTORY ............................................................................................................................1
DEPARTMENT OF HSEQ ..........................................................................................................1
IMPORTANCE....................................................................................................................1
PERSONAL PROTECT EQUIPMENTS ............................................................................1
DEALING WITH FIRE HAZARDS ...................................................................................2
DEPARTMENT OF OPERATIONS ...........................................................................................3
HEAVY CRUDE UNIT .................................................................................................................4
INTRODUCTION ...............................................................................................................4
CRUDE OIL ...................................................................................................................................4
PLANT FEED ................................................................................................................................5
PLANT PRODUCT .......................................................................................................................6
PLANT SECTIONS .......................................................................................................................6
1ST PRE-HEAT TRAIN .................................................................................................................6
DESALTING SECTION ...............................................................................................................7
FUNCTION OF DESALTIONG .........................................................................................7
DESALTING AT HCU .......................................................................................................8
2nd PRE-HEAT TRAIN .................................................................................................................9
HEAVY CRUDE FRACTIONATOR CHARGE HEATER ...............................................9
ATMOSPHERIC FRACTIONATION ......................................................................................11
PUMP-AROUNDS ............................................................................................................12
TCR ....................................................................................................................................13
MCR...................................................................................................................................14
LCR ....................................................................................................................................14
SIDE-STRIPPERS .............................................................................................................14
LIGHT WEIGHT KEROSENE .................................................................................................15
HIGH SPEED DIESEL ...............................................................................................................16
LIGHT DIESEL OIL ..................................................................................................................17
FRACTIONATOR BOTTOM....................................................................................................18
INTRODUCTION
Attock Refinery Limited (ARL) is the pioneer in crude oil refining in the country with its
operations dating back to the early nineteen hundreds (1900s). Backed by a rich experience of
more than 80 years of successful operations, ARLs plants have been gradually upgraded / replaced
with state-of-the-art hardware to remain competitive and meet new challenges and requirements.
HISTORY: It all began in February 1922, when two small stills of 2,500 barrel per day (bpd)
came on stream at Morgah following the first discovery of oil at Khaur where drilling started on
January 22, 1915 and at very shallow depth of 223 feet 5,000 barrels of oil flowed. After discovery
of oil in Dhulian in 1937, the Refinery was expanded in late thirties and early forties. A 5,500 bpd
Lummus Two-Stage-Distillation Unit, a Dubbs Thermal Cracker Lubricating Oil Refinery, Wax
Purification facility and the Edeleanu Solvent Extraction unit for smoke-point correction of
Kerosene were added. There were subsequent discoveries of oil at Meyal and Toot (1968).
Reservoir studies during the period 1970-78 further indicated high potential for crude oil
production of around 20,000 bpd. In 1981, the capacity of Refinery was increased by the addition
of two distillation units of 20,000 and 5,000 bpd capacity, respectively. Due to their vintage, the
old units for lube/ wax production, as well as Edeleanu, were closed down in 1986. In 1999, ARL
commenced JP-1 pipeline dispatches and in 2000, a Captive Power Plant with installed capacity
of 7.5 Megawatt was commissioned. Another expansion and up gradation project was completed
in 1999 with the installation of a Heavy Crude Unit of 10,000 bpd and a Catalytic Reformer of
5,000 bpd. ARLs current nameplate capacity stands at 43,000 bpd and it possesses the capability
to process lightest to heaviest (10-65 API) crudes.
DEPARTMENT OF HSEQ
IMPORTANCE:
As working for an oil refinery, where we are dealing with huge quality of hydrocarbons and
inflammables etc., it is necessary to take some special measurements and precautions to avoid any
major harms i.e. life loss.
Hence, to ensure health and safety of its employees, contractors, and customers and work for
continual improvements in Health, Safety, Environment and Quality systems, ARL has a
department to manage these affairs, under the name tag HEALTH, SAFETY, ENVIRONMENT
& QUALITY (HSEQ).
Goggles:
Eyes are the most sensitive part of a human body, to protect them from hazardous
gasses and chemicals, goggles must be used on field.
On field, there can be some maintenance of any equipment for which all chemicals
are drained out, so protect our feet from such hazardous chemicals proper dedicated
shoes must be wore on field.
Ear-muffs:
DEPARTMENT OF OPERATIONS
PLANTS:
Operations Department is the largest department in Attock Refinery Limited. Its staff operates:
1.
2.
3.
4.
5.
It also controls an effluent treatment plant for producing prime quality products in an environment
friendly manner.
PRODUCTS:
The products include LPG, Premium Motor Gasoline, Jet Fuels, Kerosene, Diesel, Furnace Fuel
Oil and various grades of Bitumen.
REFINING CAPACITY:
All crude is extracted with in Pakistan.
CRUDE OIL
PHYSICAL PROPERTIES:
Crude oil is a dark, sticky liquid which scientifically speaking is a hydrocarbon. Crude oil is highly
flammable and can be burned to create energy.
COMPOSITION:
Crude oil is a compound containing carbon and hydrogen, with or without non-metallic elements
such as oxygen and sulfur.
The hydrocarbons present in crude oil are classified into three general types:
Paraffins
Oelifins
Naphthenes
Aromatics
The basic raw material for refinery is crude oil. The chemical compositions of crude oils are
uniform, but their physical characteristics vary widely. The elementary composition of crude oil
usually falls within the following ranges:
Carbon
Hydrogen
Sulfur
Nitrogen
84-87%
11-14%
0-3%
0-0.6%
EXTRACTION:
Crudes from different sources have different make-ups. Some may have more of the valuable
lighter hydrocarbons and some may have more of the heavier hydrocarbons.
When crude oil comes out of a well (especially an undersea well), the crude oil is often mixed with
gases, water and sand. It forms an emulsion with the water that looks a bit like caramel.
The main Methods to extract the crude oil are:
1. Gravimetric method
2. Magnetic method
3. Seismic method
PLANT FEED
The feed of Heavy Crude Unit is Heavy Crude Oil and Light Crude Oil which is extracted from
all over Pakistan.
PLANT PRODUCTS
The unit produces:
NAPHTHA
KEROSENE
HIGH SPEED DIESEL (HSD)
LIGHT DIESEL OIL (LDO)
JUTE BATCHING OIL (JBO)
FURNACE FUEL OIL (FFO)
LIQUEFIED PETROLEUM GAS (LPG)
PAVING GRADE ASPHALTS
PLANT SECTIONS
The Heavy Crude Unit (HCU) in ARL is a fully integrated two stage crude distillation unit and
comprise of the following sections:
1. 1st Pre-Heat Train
2. Desalting
3. 2nd Pre-Heat Train
4. Atmospheric Fractionation Section
5. Vacuum Tower Section
6. Naphtha Stabilization
HOT STREAM
Light Vacuum Gas Oil (LVGO)
/ Vacuum Tower TCR
Fractionator Overhead
HC-E-004AB
Feed / HSD
HC-E-005AB
Feed / LDO
Feed / Fractionator MCR
HC-E-006
HC-E-007
DESALTING SECTION
After 1st Pre-Heating the Crude is desalted in the following Desalters in Series:
FUNCTION OF DESALTING:
Desalters are originally used to clean up the feed of distillation unit. Desalting reduces the salt
fouling and corrosion in exchangers and pipelines. Contaminants of crude oil may remove by
electrical or chemical desalting and both can also be used together. There is lot of process variables
involved in crude desalting.
7
HC-E-010
HC-E-011
HC-E-012
HC-E-013
HC-E-009A
HOT STREAM
Furnace Fuel Oil (FFO)
Fractionator Middle Circulating
Reflux (MCR)
Vacuum Tower Lower Circulating
Reflux (Vac. LCR) / HVGO
Asphalt
Fractionator Lower Circulating
Reflux (LCR)
Furnace Fuel Oil (FFO)
DESIGN TEMPERATURE
380 oC
500 oC
10
Discharge
P051
Fractional
Long
Ciruculation
Process
Water
HCE001
Demulsifiers
FI
Feed
(HeavyCrude)
BrodieMeter
Filter
FT48A
FCV48B
HCP001A/B
HCE002A
HCE002B
HCE003A
HCE004A
HCE003B
HCE004B
HCE006
HCE005A
HCE007
Desalter
Stage I
HCV051
HCE005B
Desalter
Stage II
HCV052
Desalter
Stage III
FCV48A
HCV053
HCE009B
Decoking
Steam
LEGEND
=1stPreHeatTrain
HCE009A
nd
=2 PreHeatTrain
HCH001
HCV001
HCE013
HCE012
HCE011
HCE010
ATMOSPHERIC FRACTIONATION
The partially vaporized Heavy Crude from heater enters the flash zone of Heavy Crude
Fractionator (HC-V-001). Atmospheric Distillation occurs in HC-V-001 and Crude is separated
into different fractions according to boiling point.
At HCU the Atmospheric distillation column is installed with 42 Trays and Crude Oil feed enters
the 37th Tray (Flash Zone) in the Heavy Crude Fractionator (HC-V-001).
The arrangement of side-streams from fractionator is as follows:
11
113 117 oC
1.1 kg/cm2G
330 339 oC
1.3 kg/cm2G
49 51 0C
0.6 kg/cm2G
PUMP-AROUNDS:
All of the heat energy used in the atmospheric tower comes from the crude preheat exchangers and
the atmospheric fired heater. To improve the energy efficiency of the crude unit, heat removal
pump-arounds are provided. These pump-around systems provide higher level heat sources which,
along with the product streams themselves, provide much of the heat used in the preheat
exchangers.
The drawn off pump-arounds are completely returned back to the Fractionator and only sensible
heat changes occur in pump-around heat exchangers.
From the Heavy Crude Fractionator (HC-V-001) the following three Pump-Arounds are drawn off
and are used effectively in the Pre-Heat Trains:
12
13
SIDE-STRIPPERS:
A substantial quantity of lower boiling point fractions exist in the intermediate distillates from
Heavy Crude Fractionator (HC-V-001) and HC-V-001 Bottom Oil the lower boiling fractions are
to be removed as far as possible to meet the specification of Flash Point. Otherwise, the light
fractions may cause the degradation of flash point as well as the reduction in the yield of lighter
fractions.
So the boiling fractions are stripped off in Three Side-Strippers:
Kerosene Stripper (HC-V-002)
High Speed Diesel Stripper (HC-V-003)
Light Diesel Oil Stripper (HC-V-004)
In Side-Strippers, the low boiling fractions are stripped off by blowing Super-heated steam from
the bottom. The effect of stripping becomes larger as the ratio of the quantity of stripping steam
injected to the liquid drawn-off from Heavy Crude Fractionator (HC-V-001 becomes higher.
In actual operation, the stripping steam flow-rate is manipulated to adjust the product flash point.
Namely, the stripping steam flow-rate increases the flash point of product increases.
14
15
16
17
FRACTIONATOR BOTTOM:
Bottoms from the bottom of the Fractionator is drawn off and boosted by Fractionator Bottom
Pump (HC-P-021 A/B) and transferred to the Vacuum Section. A part of the bottom is spilt at the
discharge line of the Fractionator Bottom Pump
The split stream is cooled in Feed / FFO Heat Exchanger (HC-E-009AB), FFO / BFW Heat
Exchanger (HC-E-032) and FFO Fin-Fan Cooler (HC-E-022) and sent to B.L.
18
VACUUM DISTILLATION
Typically atmospheric residue contains gas oils that could not be recovered in the atmospheric
tower due to the limitations imposed on the heater outlet temperature by concerns over thermal
cracking. The temperature at which hydrocarbons vaporize is a function of pressure so that if the
pressure is lowered, the hydrocarbons will vaporize at a temperature lower than the temperature at
which thermal cracking occurs.
The major components of the vacuum section are the vacuum heater and the vacuum tower. By
operating the vacuum tower at an extremely low pressure - near full vacuum - the valuable gas oils
in the residue can be vaporized and recovered.
Pressure drop is critically important in the vacuum tower. Extensive use is made in the tower of
low pressure drop contacting beds such as grid and structured and random packing. Vacuum tower
flash zones typically include specially design devices called galleries to assist in separating the
vapor and liquid and providing a uniform distribution of vapor across the cross-section of the first
contacting bed.
The bottom of Heavy Crude Fractionator is heated with Vacuum Charge Heater (HC-H-002) to
305 317 0C. The partially vaporized bottoms from Heavy Crude Fractionator (HC-V-001) enters
flash zone of Vacuum Tower (HC-V-005), which has 6 theoretical plates with packing beds.
The products of Vacuum Distillation are:
In a vacuum tower making products to be used for as feed to fuels conversion units, most of the
vapor from the wash zone is condensed in the heavy gas oil (HVGO) section, the section
immediately above the wash section. Cooling is provided using a recycle stream that preheats the
crude in the atmospheric section preheat exchangers.
Residual vapors from the HVGO section are condensed in light vacuum gas oil (LVGO) section.
Any hydrocarbon vapors that leave the LVGO section go to the vacuum system and are disposed
of in the refinery flare.
The internals of the Vacuum Tower consists of the following 6 sections from the top:
1.
2.
3.
4.
5.
6.
19
65 mmHgA
62 65 0C
85 mmHgA
304 311 0C
760 mmHgA
35 0C
NAPHTHA STABILIZATION
REFLUX TO HC-V-001:
Overhead vapors from the top of Fractionator is condensed by Feed / Fractionator OVHD Heat
Exchanger (HC-E-002 A/B) and Fractionator OVHD Trim Cooler (HC-E-015). Neutralizing
Amine and Filming Amine are injected into Fractionator OVHD to neutralize acids at upstream of
HC-E-002 A/B.
The condensate from Trim Cooler flows into Fractionator OVHD Receiver (HC-V-007). Water is
drained from bottom and liquid from the Receiver is boosted by Fractionator Reflux Pump (HCP-005 A/B) and a part of stream from the discharge is sent back to HC-V-001 as Reflux. The
remaining part is sent to Naphtha Stabilizer (HC-V-006).
20
PV36B
HCE002A
HCE002B
LP
P2
HCE015
RefluxtoHCV001
HCV007
FV10
FT10
WatertoTK001
LPG
HCV001
HCP005A/B
FV11
HCE024
FT11
NaphthaStorage
(FBRN)
HCE014
HCE024
HCE025