WINTER TRAINING REPORT

Indian Oil Corporation Ltd, Haldia

Duration: 08/01/2018 – 24/01/2018

Submitted by:

Devargya Chakraborty (15/CHE/21)

Saheb Rana (15/CHE/38)
Sayak Dutta (15/CHE/44)
Soumya Chatterjee (15/CHE/51)
Souvik Dandapat (15/CHE/52)

CHEMICAL ENGINEERING

HALDIA INSTITUTE OF TECHNOLOGY

 TABLE OFCONTENT

1. About IOCL .
2. Refineries.
3. Pipelines.
4. Oil movement and storage unit.
5. Fuel oil block.
6. Lube oil block.
7. Diesel Hydrodesulphurization.
8. Once Through Hydrocracking Unit.
9. LPG loading & unloading station.
10. Effluent Treatment Plant.
11. Bitumen Filling Station.
12. Conclusion
13. Acknowledgement.
14. Thank you.
 About I.O.C.L

Indian Oil Corporation (Indian Oil) is India's largest commercial enterprise, with a sales turnover of Rs. 4,38,710 crore
(USD 65,391 million) and profits of Rs. 19,106 crore (USD 2,848 million) for the year 2016-17. The improvement in
operational and financial performance for FY 2016-17 reflected in the market capitalization of the Company, which
grew two-fold, from Rs. 95,564 crore as on 31st March 2016 to Rs. 1,87,948 crore as on 31st March 2017. In view of
its rising share price and market capitalisation, Indian Oil was included in the Nifty50 index (NSE benchmark index of
50 best performing corporates). Indian Oil is ranked 161st among the world's largest corporates (and first among Indian
enterprises) in the prestigious Fortune ‘Global 500’ listing for the year 2016.
 Refineries
 Digboi Refinery

The Digboi Refinery was set up at Digboi in 1901 by Assam Oil Company Ltd. The Indian Oil Corporation Ltd (IOC)
took over the refinery and marketing management of Assam Oil Company Ltd. with effect from 1981 and created a
separate division. This division has both refinery and marketing operations. The refinery at Digboi had an installed
capacity 0.50 MMTPA (million metric tonnes per annum). The refining capacity of the refinery was increased to 0.65
MMTPA by modernization of refinery in July, 1996. A new delayed Coking Unit of 1,70,000 TPA capacity was
commissioned in 1999. A new Solvent Dewaxing Unit for maximizing production of microcrystalline wax was installed
and commissioned in 2003. The refinery has also installed Hydrotreater-UOP in 2002 to improve the quality of diesel.
The MSQ Upgradation unit has been commissioned. A new terminal with state of the art facility is under construction and
expected to be completed by 2016.

 Guwahati Refinery (Assam)

The Gujarat Refinery is an oil refinery located at Koyali (Near Vadodara) in Gujarat, Western India. It is the Second
largest refinery owned by India Oil Corporation after Panipat Refinery. The refinery is currently under projected
expansion to 18 MMTPA.
Haldia Refinery
The Haldia Refinery for processing 2.5 MMTPA of Middle East crude was commissioned in January, 1975
with two sectors - one for producing fuel products and the other for Lube base stocks.

Gujarat Refinery
The Gujarat Refinery is an oil refinery located at Koyali (Near Vadodara) in Gujarat, Western India. It is the
Second largest refinery owned by Indian Oil Corporation after Panipat Refinery. The refinery is currently under
projected expansion to 18 MMTPA.

 Barauni Refinery
Barauni Refinery in the Bihar state of India was built in collaboration with the Soviet Union at a cost of Rs.49.4
crores and went on stream in July, 1964. The initial capacity of 1 MMTPA was expanded to 3 MMTPA by 1969.
The present capacity of this refinery is 6.100 MMTPA. A Catalytic Reformer Unit (CRU) was also added to the
refinery in 1997 for production of unleaded motor spirit. Projects are also planned for meeting future fuel quality
requirements.

Bongaigaon Refinery
Bongaigaon Refinery is an oil refinery and petrochemical complex located at Bongaigaon in Assam. It was
announced in 1969 and construction began in 1972.
 Paradip Refinery
Paradip refinery is the 11th refinery being set up by Indian Oil Corporation in Paradip town in the state of Odisha.
The installed capacity of refinery was 15 MMTPA.
 Mathura Refinery
The Mathura Refinery, owned by Indian Oil Corporation, is located in Mathura, Uttar Pradesh. The refinery processes low
Sulphur crude from Bombay High, imported low Sulphur crude from Nigeria, and high sulphur crude from the Middle East.
The refinery, which cost Rs.253.92 crores to build, was commissioned in January, 1982.
Construction began on the refinery in October 1972. The foundation stone was laid by Indira Gandhi, the former prime minister
of India. The FCCU and Sulphur Recovery Units were commissioned in January, 1983. The refining capacity of this refinery
was expanded to 7.5 MMTPA in 1989 by debottlenecking and revamping. A DHDS Unit was commissioned in 1989 for
production of HSD with low sulphur content of 0.25% wt. (max.). The present refining capacity of this refinery is 8.00
MMTPA.

 Panipat Refinery

Indian Oil Company's (IOC) seventh refinery is located at Panipat, 125km from Delhi, in the state of Haryana in northern India.
The main units of the facility are a once-through- hydrocracker (OHCU), a residual fluid catalytic cracker and a continuous
catalytic reformer unit, as well as other secondary treatment units.
 IOCL Pipelines
IOCL operates a network of about 12848 km long crude oil, petroleum product and gas pipelines.
Map for IOCL Pipelines throughout the country.
OIL MOVEMENT AND STORAGE UNIT

This unit plays an important role in the storage of imported crude brought by tankers. Refinery storage tanks are
used in storage of crude oil and finished petroleum products. Products from these storage tanks are dispatch for
marketing by tankers, wagon, drums, cylinders etc. The mode of dispatch depends on the distance to be traversed
and on the capacity of the pump. For the pumping of highly viscous oils, positive displacement type pump are
used where as in the case of non-viscous oil centrifugal pump are used
Pretreatment takes place in two ways:
Field separation
Crude desalting
Field separation is the first step to remove the gases, water and dirt that accompany crude oil coming from the
ground and is located in the field near the site of the oil wells.
The field separator is often no more than a large vessel, which gives a quieting zone to permit gravity separation of
three phases: gases, crude oil and water (with entrained dirt).

Crude Desalting is a water washing operation performed at the refinery site to get additional crude oil clean up.

 Crude Oil Desalting consists of

 Purifying process
 Remove salts, inorganic particles and residual water from crude oil
 Reduces corrosion and fouling
EFFECT OF CRUDE CHARACTERISTICS:
The Various Units
• FUEL OIL BLOCK (FOB)

• LUBE OIL BLOCK (LOB)

• DISEL HYDRO DI-SULPHURIZATION (DHDS)

• HYDRO-CRACKING UNIT.

• LPG LOADING & UNLOADING STATION.

• BITUMEN FILLING STATION.

• EFFLUENT TREATMENT PLANT.

FUEL OIL BLOCK (FOB)

• Crude desalination unit

• Catalytic reforming unit-1,2
• Atmospheric distillation unit -1,2
CRUDE OIL DISTILLATION (CDU)
INTRODUCTION

Refining of crude oils or petroleum essentially consists of primary separation processes and secondary conversion processes. The petroleum
refining process is the separation of the different hydrocarbons present in the crude oil into useful fractions and the conversion of some of the
hydrocarbons into products having higher quality performance. Atmospheric and vacuum distillation of crude oils is the main primary
separation processes producing various straight run products, e.g., gasoline to lube oils/vacuum gas oils (VGO). These products, particularly
the light and middle distillates, i.e., gasoline, kerosene and diesel are more in demand than their direct availability from crude oils, all over the
world.

PRETREATMENT OF CRUDE OILS

Crude oil comes from the ground, which contains variety of substances like gases, water, dirt (minerals) etc. Pretreatment of the crude oil is
important if the crude oil is to be transported effectively and to be processed without causing fouling and corrosion in the subsequent operation
starting from distillation, catalytic reforming and secondary conversion processes.

IMPURITIES: - Impurities in the crude oil are either oleophobic or oleophilic.

OLEOPHOBIC IMPURITIES: - Oleophobic impurities include salt, mainly chloride & impurities of Na, K, Ca& Mg, sediments such
as salt, sand, mud, iron oxide, iron sulphide etc. and water present as soluble emulsified and /or finely dispersed water.

OLEOPHILIC IMPURITIES: - Oleophilic impurities are soluble and are sulphur compounds, organometallic compounds, Ni, V, Fe and
As etc., naphthenic acids and nitrogen compounds.
DISTILLATION

Desalted crude flows to atmospheric and vacuum distillation through crude pre flashing section. Atmospheric
distillation column (ADU) and vacuum distillation column (VDU) are the main primary separation processes
producing various straight run products, example, Gasoline to lube oils/vacuum gas oils (VGO). These products,
particularly the light and middle distillates, i.e., Gasoline, kerosene and diesel are more in demand than their
direct availability from crude oils, all over the world.
Crude oil distillation consists of atmospheric and vacuum distillation. The heavier fraction of crude oil obtained
from atmospheric column requires high temperature. In order to avoid cracking at higher temperature the
heavier fraction are fractionated under vacuum.
ATMOSPHERIC COLUMN: -
Various steps in atmospheric crude oil distillation are -
 Preheating of Desalted crude
 Pre-Flash
 Distillation
 Stabilization of Naphtha

PRODUCTS OF ADU: -
Major product from atmospheric column are light gases and LPG, light naphtha, medium naphtha, heavy
naphtha, kerosene, gas Oil(diesel),atmospheric residue.
 Unstabilized Naphtha consists of LPG, naphtha and light gases (C-5 115C) Intermediate Naphtha
(Bombay High) (135°C) Solvent Naphtha
 Heavy Naphtha (130-150C) routed to diesel or naphtha.
 Kero/ATF (140-270/250C)
 Light Gas Oil (250/270-320C)
 Heavy Gas Oil (320-380C)
 Reduced Crude Oil
Fig:- Typical flow diagram of crude oil distillation.
LUBE OIL BLOCK (LOB)

• Vacuum Distillation Unit

• Furfural Extraction unit
• Catalytic Dewaxing unit
• Hydro-Finishing unit
 VACUUM DISTILLATION COLUMN (VDU)

The bottom product also called reduced crude oil, from the atmospheric column is fractionated in the vacuum column. Reduced
crude oil is very heavy compared to crude oil distilling under pressure requires high temperature. Distillation under vacuum
permits fractionation at lower temperature which avoid cracking of the reduced crude oil and coking of the furnace tube.
Vacuum is maintained using three stage steam ejector. The reduced crude oil from atmospheric column at about 360oC is heated
and partially vaporized in the furnace. The temperature in the flash zone of the tower is controlled by the furnace coil outlet
temperature. The preheated and partially vaporized reduced crude enters the flash zone of vacuum column where it is
fractionated into various streams.

PRODUCTS FROM VDU:

Various products from VDU are Light gasoil, Heavy gas oil, light lube distillate, medium lube distillate, and heavy lube distillate
and vacuum column residue

OPERATING PRESSURE OF VACUUM COLUMN:

 About 90-95 mm Hg at the top and
 About 135-140 mm Hg at the bottom
Various Streams From Atmospheric And Vacuum Distillation Columna
DISEL HYDRO DI-SULPHURIZATION (DHDS)

• Hydrotreating unit
• Amine absorption unit
• Sulphur recovery unit
Diesel Hydrodesulphurization (DHDS) / Hydrotreating (DHDT) Technology

In view of growing importance of Hydro processing, and to achieve leadership in developing, adopting and assimilating state-
of-the-art technology for competitive advantage, Indian Oil- R&D initiated a systematic program to build up knowledge base in
hydro processing technology. With this expertise, Indian Oil R&D has become leader in providing technical services to the
refineries in the key areas of process optimization, troubleshooting and performance monitoring. Indian Oil-R&D in
association with EIL (Engineers India Limited) developed its proprietary Diesel Hydrodesulphurization (DHDS)/
Hydrotreating (DHDT) technology.

Advantages
 Indigenous Process design & technology
 Capable of producing ultra-low Sulphur meeting BS-IV diesel specifications
 Competitive with foreign licensors
 Proprietary DHDS/DHDT catalyst system so as to offer a complete package.
 Design and Engineering experienced of EIL
 Once Through Hydrocracking Unit
OHCU comprises of three units:
1. Hydro cracker
2. Hydrogen Generation unit
3. Nitrogen generation unit
• Hydrocracker
Feed: Straight run gas oil, Vacuum gas oils, Cycle oils, Coker Gas oils, thermally cracked
stocks, Solvent de asphalted residual oils, straight run naphtha, cracked naphtha.\
Product: Liquefied petroleum gas (LPG), Motor gasoline, Reformer feeds, Aviation turbine
fuel, Diesel fuels, heating oils, Solvent and thinners, Lube oil, FCC feed
Catalyst used
• Hydro pre-treatment catalyst
• Hydro cracking catalyst
Effect of various parameter on the catalyst:-

Variable Change and effect in catalyst life

Feed rate Increase-decrease

conversion Increase-decrease

Hydrogen partial pressure Increase-increase

Reactor pressure Increase-increase

Recycle gas rate Increase-increase

Recycle gas purity Increase-increase

LPG loading & unloading station

IOCL refinery, which is located in the upper Midwest, runs into problems pumping liquefied
petroleum gas (LPG) from storage bullets to tanker trucks during the summer. Except for low tank
level can pump 600 gpm in the winter without any issues but have trouble pumping at all by late
morning in the summer. That's when we divert propane, with some difficulty, to underground
pipelines. The bullet pressure reliefs are set at about 500 psig. The operating pressure starts at
about 140 psig when the bullets are full but is only about 105 psig at about 45% full, which is as
low as we can go. We feed four bullets at a time to the pump. During filling, pressure can spike at
above 200 psig on a hot day.

PROBLEMS FACED WHILE LOADING;-

• Vapour-lock of the valve.
• Controlling the tank operating pressure.
• Taking proper care of the pump issues.
A LPG loading center
Bitumen Storage And Filling Plant.(BFS)

I.O.C.L is one of the Leading manufacturer and supplier in Bitumen Storage And Filling
Plant. The storage tank & filling plant offered by us is checked on numerous parameters so as
to deliver a defect free range. We manufactured this storage tank using premium grade material
and progressive technology in tandem with set industry standards. Also, our storage tank is
known among customers for its safe & reliable storage.
Features:
• Compact design
• High efficiency
• Perfect finish
Effluent treatment plant
Effluent Treatment Plant or ETP is one type of waste water treatment method which is particularly
designed to purify industrial waste water for its reuse and it’s aim is to release safe water to
environment from the harmful effect caused by the effluent. Industrial effluents contain various
materials, depending on the industry. Some effluents contain oils and grease, and some contain toxic
materials (e.g., cyanide). Effluents from food and beverage factories contain degradable organic
pollutants. Since industrial waste water contains a diversity of impurities and therefore specific
treatment technology called ETP is required. The ETP Plant works at various levels and involves
various physical, chemical, biological and membrane processes to treat waste water from different
industrial sectors like chemicals, drugs, pharmaceutical, refineries, dairy, ready mix plants & textile
etc.

Benefits of ETP:-
1.To clean industry effluent and recycle it for further use.
2. To reduce the usage of fresh water in industries.
3. To preserve natural environment against pollution.
4. To meet the standards for emission of pollutants set by the Government & avoid heavy penalty.
5. To reduce expenditure on water acquisition.
Representation Of Effluent Treatment Plant In IOCL
 Conclusion

• Indian Oil Corporation (Indian Oil) is India's largest commercial enterprise

• The various units that are present in the refinery are FOB, LOB, DHDS, LPG and ETP.

• The various products that are been produced are Lube oil, motor spirit, diesel, ATF.

• One of the India’s three lube oil refineries producing high grade lube base feed stocks.

• Indian Oil Corporation being the sole producer of Jute Batching Oil.

• Incorporating 70% indigenous equipment's for the first time in India

 Acknowledgement

We are thankful to all the officials and staffs of Indian Oil Corporation Limited, Haldia
Refinery for helping us to complete our training.

We are also thankful to chemical department for giving us an opportunity to present the report.
Thank you