SUMMER TRAINING (IOCL BONGAIGAON)

Submitted By Ashok Paliwal

12210008, CH 407 IDD 4th year, Chemical

INDUSTRY (IOCL) OVERVIEW

Established in 1964

Refining capacity : 65.7 MMTPA ( 1.31 million barrels per day)

Refineries at Barauni, Gujrat, Mathura, Guwahati, Bongaigaon, Panipat, Haldia

Commissioned in February 1979 as BRPL

The company became a subsidiary of IndianOil (IOC) on 29 March 2001.

Designed by Engineers India Ltd.

Capacity: 2.35 MMTPA (1.5 MMTPA Ravva Crude , 0.85 MMTPA Assam Crude)

CRUDE OIL SOURCE: Assam crude(Sulphur 0.3%), Ravva Crude (Sulphur 0.1%, from the Ravva oil field of Andhra Pradesh) & Imported

Crude (from Nigeria , Indonesia) Imported crude oil is received through Haldia – Barauni crude pipeline up to Barauni & from Barauni to BGR by

reverse pumping through oil pipeline.

PRODUCTS: LPG ,Naphtha, MS (Euro-III), Kerosene, HSD(High Speed Diesel), LDO(Light Diesel Oil), LVFO (Light Viscosity Fuel

Oil),LSHS(Low Sulfur Heavy Stock).

BGR Refinery

BGR AT A GLANCE

1.CRUDE DISTILLATION UNIT (CDU) Capacity: 1.35 MMTPA (1ST UNIT) , 1.00 MMTPA (2ND UNIT) Products: L.P.G. ,Straight Run Naphtha ,Reformer Feed Naphtha, Raw Kerosene and Diesel Reduced

Crude Oil (RCO)

2. Delayed Coker Unit(DCU) Capacity: 500000 TPA Function: Convert crude oil into fuel gas , LPG ,Naphtha, Gas Oil , Fuel Oil & RCO

3. CATALYTIC REFORMER UNIT (CRU) Capacity: 160,000 MTA Feed: Reformer Feed Naphtha

BGR has 2 CDU units

Capacity: 2.35 MMTPA

CDU Unit Consist of Following Sections: Crude preheat train and Desalter Fired heater Crude Distillation Section Stripper Stabilizer Naphtha Splitter LPG Wash Section

Crude Distillation Unit

1.Storage tank: No of tanks : 7 Type: Floating Head Capacity of tank :20,000 kl2. Pump: Centrifugal Pump Pressure : 55 Kg/ cm23. Preheat exchanger: Series of shell & tube heat exchanger Crude oil is preheated up to about 130 °C Hot medium: RCO Cold medium: Crude Oil

Crude Preheat Train & Fired Heater

3.ELECTRIC DESALTING :

The desalter is an electrostatic coalesce used for purification of crude from sludge, salts and corrosion inducing salts

4. 2nd Preheat Exchanger:

Desalted crude oil heated up to about 223 -227 °C

Hot medium: LVFO

Cold medium: Desalted crude oil

5. Furnace:

Type: Natural draft , vertical cylinder , two passes, with convection and radiation section

Has 12 burners.

Preheated crude oil heated to about 358 0C

DesalterWater WashingHeatingCoalescenceSettling Rate

CRUDE DISTILLATION & STRIPPERSHeight of Distillation column: 50m

Number of Trays: 38

Feed from the fired heater enters the column under tray #5

Fractionator’s : Temprature:350 °C Pressure :1.3 Kg/cm2

Products : Distillate Bottom Products

Overhead: Overhead vapors goes to the overhead condenser at about 142 °C & Condensate is collected in reflux drum

A part of this condensate is sent to the crude column as top reflux & balance quantity goes as Stabilizer feed

Bottom Product: Reduced crude oil

Products Withdrawn Temp Tray No

Kero I 225 23

Kero II 260 15

Gas Oil 309 9

Distillate

Column has 30 trays

Top Temp: 65°C

Top Pressure: 10 Kg/cm2

The purpose of stabilizer is to stabilize naphtha by separating out liquefied petroleum gas (LPG) & others C-4 components

Kero II CR is used as heating medium for stabilizer reboiler

LPG withdrawn from Stabilizer reflux drum is first washed with caustic and then washed with water and then is sent to Horton sphere for storage

Stabilizer

The stabilized naphtha is further split into light naphtha (50-110 °C) and heavy naphtha (110-180 °C) in Splitter-I

Splitter-I bottom is further split into reformer feed naphtha (110-147 °C) and Kero component

Reboiler heating media for Splitter-II is reduced crude oil from main fractionator column bottom

Naphtha Splitter

CDU 1 v/s CDU 2CDU I CDU II

Natural Draft type furnace Forced draft type furnace

Number of burners 11 Number of burners 8

Fuel consumption 1.45% of the throughput Fuel consumption of 1.35% of throughput

Capacity 370 Kg/hr Capacity 450 Kg/hr

Double pass furnace Single pass furnace

No of preheat exchanger 11 No of preheat exchanger 14