Panipat refinery

1. INTERNSHIP
EXPERIENCE
INSTITUTE OF CHEMICAL TECHNOLOGY –
INDIAN OIL CAMPUS

2. About Indian Oil
 Formed in 1964 , merging of Indian
Refineries and Indian Oil Company Ltd.
P.A.Gopalakrishnan , 1st Chairman
 2010, Maharatna PSU
 11 refineries , Combined refining capacity is
80.7MMTPA I.e. 33% of domestic refining
capacity
 2 SPM at Vadinar & 3 SPM at paradip
 16 new grades of crude processed ,11 of
US origin (2017-2018)

3. PANIPAT REFINERY
 Seventh refinery , Technically most
advanced refinery complex
 Total capacity – 15 MMTPA , plan to
augment to 25 MMTPA
 Major secondary units are CRU ,
OHCU , VBU ,BBU etc.
 1st refinery to switch over from BS-III to
BS – IV and now supply of more
ecofriendly BS-VI to NCR, Delhi
 Refinery houses PX-PTA plant and
Naphtha Cracker complex

4. PANIPAT REFINERY EXPANSION PROJECT {PREP}
 PR capacity augmented from 6MMTPA to
15MMTPA by 2010
 PREP was designed to process high Sulphur
crude.
Types of Crude :
1)Low Sulphur : Quaiboe, Boney light
2)High Sulphur: Kuwait, Iran Mix, Basrah light,
Upper Zakhum, Suez mix, Furrial etc
 CRUDE PROCESSED : ARAB MIX
 CHECK CRUDE : QUAIBOE

5. PIPELINES
 14,189 km long crude oil , petroleum product and gas pipeline
 94.79MMTPA of oil & 9.5MMSCMD of gas (Total processing capacity)
 Safest , cost-effective , energy efficient and environment friendly mode of
transportation
 4 product pipelines – 1)PRPL
2)PAJPL
3) PBPL
4)PBATF
 Panipat-Jalandhar LPG pipeline – 273km pipeline
 Intermediate delivery station for LPG bottling plant at Nabha (Patiala)

6. CRUDE OIL
 85% of crude oil is imported by
India and aims to bring down by
67% by 2022
 Crude oil reserves – 604.10 MT
(2017)
 Crude oil is carried by VLCC via
sea only
 SPM (Single point Mooring )–
Floating buoy for handling of
liquid cargo
 Indian oil operates 2 SPM at
Vadanir & 3 SPM at paradip for
transferring crude oil

7. ATMOSPHERIC AND VACUUM DISTILLATION UNIT
 AVU = CDU(CRUDE DISTILLATION UNIT) +
VDU( VACUUM DISTILLATION UNIT)
 Capacity = 6 MMTPA of Arab Mix crude (
50:50; AL:AH). Check crude : QUAIBOE
 Distillation is the most primary process that is
used for separation of the components of
crude oil due to the varied boiling point
temperature.
 Major units :
 1) Desalter
2) Preheat trains and Flash vessel
3) Atmospheric Heater
4) Atmospheric column
5) Vacuum heater
6) Vacuum column

8. CRUDE DESALTING
 Desalting consists of three major process
•Heating
•Mixing
•Settling
 In desalting , there is formation of emulsion
of oil and water
 Demulsification of emulsion using strong
electric field(A.C).
 Two stage desalting operation and
countercurrent mechanism of desalted
water

9. ATMOSPHERIC DISTILLATION COLUMN
 55 trays, 6 at the bottom are the bottom stripping
section of the column.
 OVHD circuit for removal of Gases and Light
naphtha.
 4 side draws and 3 Refluxes
 Major products of atmospheric column are :
1) Fuel gas and LPG
2) Light Naphtha
3) Heavy naphtha
4) kerosene/ ATF
5) Light Gas Oil
6) Heavy Gas Oil
7) Reduced Crude Oil( RCO+)

10. VACUUM DISTILLATION COLUMN
 RCO from atmospheric column is passed
through vacuum heater before being sent
to vacuum column .The feed from
vacuum heater is send to the vacuum
column at the flash zone above tray #6.
 The vacuum heater flash zone pressure
is at 60-70 mm of Hg and temperature is
398.7/382˚c for AM crude or Quaiboe
crude.
 The various products obtained from
vacuum column :
1) Vacuum diesel
2) Light vacuum Gas Oil
3) Heavy vacuum Gas Oil
4) Vacuum residue
5) Vacuum wax and slop

11. HYDROCRACKING UNIT(HCU)
 PURPOSE:
The process objective of Hydrocracker unit (HCU) is to produce highest quality
and quantity of High-speed Diesel and LPG products from gas oil feed stocks,
 UNIT CAPACITY:-
The design capacity for the Hydrocracker is 1.7 MMTPA. The feed to the unit is
a mixture of:
 Vacuum Gas Oil (VGO) from Vacuum distillation column.
 Heavy Coker Gas Oil (HCGO) from Delayed Coking unit.
 Heavy Gas Oil (HGO) from Atmospheric distillation column

12. PROCESS:-  HCU mainly consist of 2
units Reaction and
fractionator section.
 Reactors are of 2 type :-
Hydrotreating Hydrocracking
reaction
 In the first reactor, which
has three beds,
predominantly feed
demetallising and
hydrotreating reactions take
place and in the second
reactor, which is having two
beds,.

13. HYDROTREATING REACTION
HYDROCRACKING REAC:TION-
Cracking Reaction
• Saturated Paraffins cracked to form lower
molecular weight olefins and paraffins
Isomerization Reactions
• Isomerisation provides branching of alkyl
groups of paraffins and opening of
naphthenic rings
• Condensation Reaction

14. FRACTIONATION SECTION:-
 The liquid hydrocarbons recovered in Hot and Cold Flash
drums of the Reaction section are steam stripped of their light
gaseous components in the Stripper Column. The vapors
recovered in the Stripper flow to a Sponge Absorber Column
 From here it is sent to side strippers from which diesel, petrol
are separated.
 This is how a 2 reactor HCU works.
 This section strips out LPG sent for amine treatment.

15. HGU (Hydrogen Generation Unit):
 To generate hydrogen (99.9%) for the downstream hydro
processing units like hydro cracker and DHDT
 Feed : Naphtha and RLNG
 Main sections in HGU :
• Removal of Sulphur in Naphtha
• Steam Reforming of Naphtha
• Shift Conversion
• Purification of Hydrogen

16. Hydrogen Generation Unit
• Pre reformer section: A adiabatic reactor and a singe bed
reactor
catalyst: RKNGR
Reactions: CnHm + nH2O  nCO + (n+m/2) H2 (ΔH
= +ve)
CO+ H2O  CO2 + H2 (ΔH = -ve)
CO + 3H2  CH4 + H2O (ΔH = -ve )
• Reformer section : Costliest section , Catalyst : R67 – 7H
• Reactions: CH4 + H2O  CO + 3H2 (∆H = +ve )
• CO + H2O  CO2 + H2

17. Pressure Swing Adsorption
 Principle: Difference in pressure to remove
impurities
 Aim: To produce 99.9% pure Hydrogen.
 Operates at High pressure
 12 Beds in pair.
 Runs on predesigned software taking in
information.
 In pairs Equalization takes place: Recovery of
hydrogen takes place in one and removal of
impurities takes place in another bed.

18. DIESEL
HYDROTREATING
UNIT(DHDT)
 To meet the BS-IV/BS-VI diesel
requirement ( minimum cetane
number 51)
 Feed : LGO(CDU) – 240-320ºc
 VD(VDU) – 370ºc , LCGO(DCU)
 CAPACITY : 3.5MMTPA
 LICENSOR : Axens
 Catalyst : Ni- Mo oxides
 Major reactions are
hydrodesulphurization ,
hydrodenitrification , Aromatic &
Olefin saturation

19. PACKINOX
 Ideal for demanding heat recovery duties in processes
with high pressure and temperature
 Low CAPEX , superior hydraulic efficiency
 Large heat transfer bundle inside a pressure vessel
 Operate at high temperature as 550°c
 Top & bottom manholes for maintenance

21. Motor spirit Quality
upgradation(MSQ)
 BS-IV(Research octane Number (RON) = 91, Motor octane number (MON) =81
 Feed: Naphtha(FCC+CCRU+AVU)
 Four units in MSQ
NHT
LICENSOR
UOP,USA
CAPACITY
410TMTPA
PENEX UOP,USA 400TMTPA
RSU AXENS,FRANCE 470TMTPA
FCC-GDS/PRIME G+ AXENS,FRANCE 370TMTPA

22. • Hydrotreat SR-Naphtha.
• Metal impurities(in ppb in
naphtha) removed.
• PENEX catalyst
poisons(sulfur,O,NH3,halide)
removed from light naphtha.
NHT(Naphtha
Hydrotreating)
FEED: SR-Naphtha from
NSU-1&2.
Reactor pressure:30-
35kg/cm2
Inlet temperature- 3150 C

23. • To concentrate the benzene and its
precursors in light reformate which is
further routed as feed to penex unit
by splitting the CRU reformate into
light and heavy reformate.
• Heavy reformate sent directly for
MS blending.
RSU(Reformate
splitter unit)
Feed-reformate ex-CRU is
feed for unit.
Designed for two cases-
• Case A-low benzene feed
• Case B-high benzene
feed.

24. PENEX
• Penex-1.to increase the octane number of
hydrotreated naphtha
2.To reduce the benzene level in the light
reformate
e.g. 1.C5H12(61.8ron) C5H12(Methyl
butane 93ron)
FCC-
GDS(PRIME
G+)
• Feed-FCC gasoline is the main feed for
the unit .the light Coker naphtha ex DCU
and pyrolysis gasoline ex-Panipat
naphtha cracker project are also part of
feed.
• Process-
• Selective hydrogenation unit
• Gasoline splitter unit
• Hydro-desulphurization unit

25. OIL MOVEMENT & STORAGE
 Blending of intermediate products
 Oil Accounting
 Dispatch of finished products
HSD TANK
CAPACITY- 40,000KL
MOUNDED
BULLETS
HORTON SPHERE

26. DYKE HVLRM
SPRINKLER FOAM COMPRESSOR
SYSTEM

27. PADC(PRODUCT APPLICATION DEVELOPMENT CENTER)
 The Laboratory building is designed to
take on an Iconic position in the refinery
complex, signifying the focus on research
and the Future.
 BLOW MOULDING :- Process of
forming a molten tube and placing the
parison or preform within a mould
cavity.

28.  ROTO MOULDING:-A heated hollow
mould which is filled with a charge
material.
 It is then slowly rotated causing the
softened material to disperse and
stick to the walls of the mould.
TUBULAR QUENCHED POLY PROPYLENE:-
• The resin is extruded & the molten material in form of
tube comes out of the circular die.
• Cooling is done
• Film is subsequently collapsed, passed through drying
unit and finally rolled up

29. TECHNICAL SERVICES
DEPARTMENT Process
Monitoring
Planning and
Coordination
Energy
Conservation
Process
projects
Offsite and
Automation

30. PANIPAT NAPHTHA CRACKER
PRODUCT APPLICATION &
DEVELEOPMENT CENTRE

31. PRESSURE SWING
ADSORPTION
HYDROGEN GENERATION
UNIT

32. CONCEPTS TO KNOW
 DISTILLATION
 VAPOUR-LIQUID EQUILIBRIUM
 HEAT EXCHANGER ( SHELL & TUBE
EXCHANGER)
 COMPRESSORS & PUMPS
 EJECTOR
 STORAGE TANKS

33. REFINERY
EXPERIENCE
 SELF –LEARNING
 OVERVIEW OF MAJOR OPERATIONS
& EQUIPMENTS
 PANIPAT NAPTHA CRACKER –
INDIA’S LARGEST OPERATING
CRACKER
 OVERVIEW OF DIFFERENT UNITS OF
PNC
 INDIAN OIL’S PADC – RESEARCH
DEVELOPMENT THRUST ON PLASTIC

34. THANK YOU