The ONGC Hazira Plant, located in Surat, Gujarat, India, is a significant sour gas-processing

complex that handles the conversion of raw well fluids into marketable products. The plant
operates 24/7. This report details the various units, their equipment, and the processes
involved in the plant's operations.

1. Gas Terminal Unit (GTU)

The GTU serves as the initial reception and separation point for the two-phase flow (sour gas
and condensate) arriving from offshore fields.

 Process in Detail:
o Receiving Two-Phase Flow: Sour gas from Bombay High arrives via 217 km
of 36" and 42" subsea pipes to Ubharat beach, and then via a 14 km pipeline
on land to the gas terminal. The two-phase flow is received in the slug catcher.
o Separation in Slug Catcher: The slug catcher separates the incoming two-
phase flow into gas and condensate streams. During normal operation, Phase-1
slug catcher (24-fingers) separates condensate from approximately 25
MMSCMD of sour gas from the 42" line, while Phase-2 slug catcher (24
fingers) separates gas and condensates from the 36" line. There are three
phases, with two working at a time and one remaining on standby. The slug
catcher utilizes different slopes (5% initially, then 0.5%) in its separating and
storage sections to facilitate gravity separation. The separated gas exits
through primary, secondary, and equalizing risers.
o Filtering: The separated gas from the slug catcher is sent for filtration to
remove any entrained condensate and solid particles. Sour gas from Phase-1
goes to an existing filtration unit, while sweet gas from Phase-2/Phase-3 slug
catcher is sent to a new filtration unit. Each new filter can treat a maximum of
580,000 SCMH (13.92 MMSCMD) of sweet gas, removing 99% of 10µ solid
particles. Each filter is equipped with automatic liquid discharge.
o Metering: After filtration, the gas goes to metering units to measure the flow
rate, compensated for pressure and temperature. Condensate from Phase-
2/Phase-3 slug catcher is also fed to a condensate metering unit to measure its
flow rate.
o Condensate Routing: The separated condensate from the slug catcher is
metered and sent to the Condensate Fractionation Unit (CFU) for further
treatment.
o Gas Routing: The filtered and metered gas is sent to the Gas Sweetening Unit
(GSU) for further processing.
o Pigging Operation: Pigs are sent from the offshore terminal once a year to
remove water sludge, foreign particles, and accumulated heavier molecules
and solids from the pipelines. The pig is retrieved at the

pig receiver, and the unit is cleaned. Precautions are taken during pig
operation, including pressure testing the trap, recalibrating sensors, and
maintaining low slug catcher condensate levels.

 Major Equipment and Types:

o Slug Catcher: Finger-type vessel. Total 2 lines, 50 MMSCMD capacity. Each
finger: 498 m length, 48" diameter, 5% slope for separation, 0.5% slope for
storage. Storage area:
 11000 m3, total capacity 22000 m3.

o Pig Receiver: Pressure vessel (Pig barrel).

o Gas Filtering Unit: Cyclone type filters.
o Metering Unit: Flow meter, pressure gauge, temperature gauge.
o Pressure Reducing Valves (PCV).
o Blow Down System.

2. Gas Sweetening Unit (GSU)

The GSU is responsible for removing hydrogen sulfide (H2S) and minimizing carbon dioxide
(CO2) from the sour gas, making it suitable for subsequent processes and consumption. There
are 8 operating trains and 1 standby train with a total capacity of 40.6 MMSCMD.

 Process in Detail:
o Gas Feedstock: The GSU receives a mixed gas composition (slug catcher gas
and CFU off-gas). Inlet pressure at battery limits:

96−54 kg/cm2 abs. Inlet temperature at battery limits:

20−33∘C.

o Absorption Section:
 Raw Gas Pre-treatment: Slug-catcher derived raw gas is first heated
in a steam heater to maintain its temperature above 25∘C to prevent
hydrate formation, controlled by steam flow. This gas is then mixed
with raw gas from the condensate treating unit.
 Knock-out Drum: The raw gas mixture passes through a knock-out
drum (KOD) where liquid carryover (water, hydrocarbon) is removed
and pumped to the condensate treating unit.
 Amine Absorption: Gas leaves the KOD and enters an amine
absorption column (C-101) where it contacts counter-currently with
an aqueous solution of Methyl Di-Ethanol-Amine (MDEA). The lean
MDEA solution, at

45∘C, enters the upper part of the column. The top tray is dry and
retains carryovers.

 Selective H2S Removal: MDEA, being a tertiary amine, selectively

removes H2S due to faster reaction kinetics compared to CO2. The
process aims to provide sufficient gas-liquid contact time to remove

H2S while partially retaining CO2.

 Sweet Gas Cooling & Separation: Treated gas, containing less than 5
ppm volume of H2S and ranging from

40∘C to 44∘C , is cooled to

 38∘C by a water cooler. Condensed water and vesicular amine
carryover are separated in the treated gas knock-out drum and returned
to the rich amine circuit. The sweet gas is then piped to the TEG
drying unit. Product

H2S content: 5 ppm Vol. Max. Product pressure at battery limits:

74.9−51.9 kg/cm2. Product temperature at battery limits:

47∘C.

o Amine Regeneration Section:

 Rich Amine Flash Drum: The rich amine solution from the bottom of
the absorber is piped to the rich amine flash drum (V-303). Sour
flashed gas from this drum contains about 200 ppm (vol.)

H2S. Rich MDEA Flash Gas pressure at battery limits:

4.5 kg/cm2abs. Temperature at battery limits:

48−55∘C.

 Fuel Gas Absorption: To meet fuel gas specifications (<5 ppm vol.
H2S), this sour fuel gas is contacted with a small lean MDEA flow in a
6-valve tray absorption tower on top of the rich amine flash drum.
 Heat Exchange & Regeneration: The rich amine solution flows from
the flash drum to the rich/lean amine exchanger. MDEA solution
stripping is accomplished in the

regenerator by vapor generated from the reboiler.

 Lean Amine Cooling & Storage: The lean amine collected at the
bottom of the regenerator is routed through an amine/amine
exchanger, cooled to 45∘C in a lean amine cooler, and sent to a large
lean amine storage tank.
 Acid Gas Handling: The hot acid-gas/steam mixture from the
regenerator overhead is cooled to 50∘C in a condenser, where water
vapor condenses. This condensed vapor is separated in the

reflux drum and pumped back to the regenerator top section. Acid gas
is sent to an acid gas header through a pressure control valve and then
to the SRU. Acid Gas pressure at Battery Limits:

1.9∗kg/cm2 abs. Acid Gas Temperature at Battery Limits:

50∘C.

o Amine Management:
 Storage Section: A large storage tank stores the total amine
circulating stream, allowing recovery during maintenance, regulating
 disturbances, simplifying solvent make-up, and enabling efficient
decantation. The tank is blanketed with fuel gas to prevent oxygen
contact and MDEA degradation.
 Filtration Package: Treats approximately 10% of the total lean amine
flow. It includes a

pre-coat filter (removes solid particles like iron sulphides and

carbonates) , an

activated charcoal bed (removes degradation products and

hydrocarbons) , and a

cartridge filter (removes entrained activated charcoal).

Sump Drum: Collects drips and drains from the unit, with collected
MDEA pumped through the filtration package to the storage tank. It's
blanketed with fuel gas to prevent degradation.
 Antifoam Package: Injects antifoam chemicals into the MDEA
circulation system at the suction of the amine charge pump to prevent
foaming.
 Major Equipment and Types:
o Absorber Column (C-101): Tray Column, 14 valve trays.
o Rich Amine Flash Drum (V-303): Vessel.
o Absorption Tower: Tray absorption tower, 6 valve trays.
o Steam Heater: Heat exchanger.
o Water Cooler: Heat exchanger.
o Rich/Lean Amine Exchanger: Heat exchanger.
o Regenerator: Column.
o Reboiler: Heat exchanger.
o Lean Amine Cooler: Heat exchanger.
o Condenser: Heat exchanger.
o Reflux Drum: Vessel.
o Knock Out Drum (KOD): Vessel.
o Pre-Coat Filter: Filter.
o Activated Charcoal Bed: Filter.
o Cartridge Filter: Filter.
o Lean Amine Storage Tank: Storage tank.
o Sump Drum: Vessel.
o Pumps: Lean Amine Filter Pump , Amine charge pump , Sump drum pump.

3. Gas Dehydration Unit (GDU)

The GDU removes moisture from the sweetened gas to prevent hydrate formation and
corrosion in pipelines. The total capacity of GDU trains is 41.0 MMSCMD with all 8 trains
operating.

 Process in Detail:
o Feed Gas Knock-Out Drum: Treated gas from the GSU enters the Feed Gas
KO Drum (V-404) to remove entrained or condensed liquids. Liquids are sent
to the rich amine flash drum (V-303). Feed pressure at battery limit:
 51.9−74.9 kg/cm2 Abs. Feed temperature at battery limits:

38∘C.

o TEG Absorption: The gas from V-404 flows to the absorption column (C-
401) where it is contacted with a lean tri-ethylene glycol (TEG) solution
(99.7% wt.). The column has 9 bubble cap trays; the feed gas enters below the
bottom tray and is scrubbed by glycol flowing counter-currently. The top dry
tray retains major carry-overs, reducing glycol losses.
o Dried Gas Scrubber: Scrubbed gas leaving C-401 passes to the dried gas
scrubber (V-401) to remove entrained glycol carry-over. The dried gas then
goes to the hydrocarbon dew point depression units. Product

H2S content: 5 ppm vol. max. Product H2O content:

85 kg/mmNm3 max (−7∘C dew point) at high pressure, 50 kg/mm Nm3 max
(−11∘C dew point) at low pressure. Product pressure at battery limits:

74 kg/cm2 (high pressure), 51 kg/cm2 (low pressure). Product temperature at

battery limits:

33∘C (high pressure), 40∘C (low pressure).

o Rich Glycol Degassing: Rich glycol from the bottom of C-401 is sent to the
Rich Glycol Degassing Drum (V-402). Due to lower operating pressure (

10 kg/cm2a), absorbed hydrocarbons are released and sent to the fuel gas
header. Condensed hydrocarbons accumulating on the surface are manually
drained to the flare header.

o TEG Filtration: Degassed rich glycol from V-402 goes to a filter package.
This includes a

cartridge filter (X-40INB) to remove solid particles from the full rich glycol
stream, and an activated carbon filter (X-402) downstream, which treats a
portion (up to 33%) of the glycol flow to remove degradation products and
hydrocarbons.

o Regeneration Section:
 Glycol Preheating: Before entering the regenerator column (C-402),
the glycol is preheated in a heating coil at the top of the regenerator.
This coil also partially condenses hot vapors, providing internal reflux.
Top temperature of C-402 is controlled from

97.8∘C to 98.4∘C.

 Heat Exchange & Regeneration: The rich glycol then flows through
a rich/lean glycol plate type exchanger (E401 A/B), where it is
heated from 52∘C to 175∘C by exchange with regenerated lean glycol.
 It then enters the regenerator column C-402, an atmospheric column
with 4 bubble cap trays.
 Reboiler & Stripper: The temperature in the regenerator reboiler
(E-402) is controlled at 204∘C by HP steam. Glycol from the reboiler
overflows to the

stripper (C-403), where it is stripped by hot dry fuel gas to achieve

99.7% wt. concentration.

 Lean Glycol Cooling & Recirculation: Hot, stripped lean glycol from
C-403 flows by gravity through the rich/lean glycol plate type
exchanger (E-401 A/B), cooling from 204∘C to 80∘C. It then goes to
the

surge drum (V-403). Lean glycol is pumped from V-403 by

lean glycol injection pumps (P-401 A/B) to the trim cooler (E-403),
where it's cooled to 45∘C by cooling water, and then returns to the
absorber C-401.

 Major Equipment and Types:

o Feed Gas KO Drum (V-404): Vessel.
o Absorption Column (C-401): Tray column, 9 bubble cap trays.
o Dried Gas Scrubber (V-401): Scrubber/Vessel.
o Rich Glycol Degassing Drum (V-402): Vessel.
o Cartridge Filter (X-40INB): Filter.
o Charcoal Filter (X-402): Filter.
o Regenerator Column (C-402): Atmospheric column, 4 bubble cap type trays.
o Regenerator Reboiler (E-402): Heat exchanger.
o Stripper (C-403): Column, end-mounted on the reboiler.
o Rich/Lean Glycol Plate Type Exchanger (E-401 A/B): Plate type heat
exchanger.
o Surge Drum (V-403): Vessel.
o Trim Cooler (E-403): Heat exchanger.
o Pumps: Lean glycol injection pumps (P-401 A/B).

4. Dew Point Depression Unit (DPD)

The DPD unit chills sweetened and dehydrated gas to remove hydrocarbon condensate,
preventing hydrate formation in long-distance pipelines like the HBJ pipeline.

 Process in Detail:
o Chill Down Section:
 Gas-Gas Heat Exchange: The feed gas from the GDU train (inlet
temp: 37.4∘C, pressure: 53.5 kg/cm3) is first cooled by the outgoing
(dew point depressed) product gas (outlet temp: 31.6∘C, outlet
pressure: 49.7 kg/cm3) in Gas-Gas Exchangers (E-501 A/B/C/D).
 Chilling in Gas Chiller: It is then finally cooled to 5∘C in a Gas
Chiller (E-502) by evaporating propane refrigerant in a closed
 circulation cycle. The gas temperature at the chiller outlet is controlled
by a chiller bypass control valve (TV-1101).
 Condensate Separation: The chilled gas is sent to a Filter-Separator
(X-501) to knock out hydrocarbon condensate, and any traces of water
and glycol.
 Product Gas Exit: The separated gas from the filter-separator
exchanges its cold partially with the incoming feed gas in the Gas-Gas
Exchangers (E-501 A/B/C/D). The gas is then sent for transportation
in the HBJ pipeline. Expected minimum temperature in HBJ pipeline is

11∘C.

 Condensate Routing: Hydrocarbon condensate from the filter-

separator is pumped by Condensate Transfer Pumps (P-501 A/B) to
the LPG unit/Condensate Fractionation Unit or Slug catcher
condensate header.
o Propane Refrigeration Section: This system supplies the refrigeration
required in the gas chiller (E-502).
 Propane Sub-cooling: Propane from the accumulator (V-502) at
45∘C flows to the propane sub-cooler (E-504) where it is sub-cooled
by cooling water to 40∘C.
 Evaporation in Chiller: It then flows to the shell side of the chiller
(E-502) through a level control valve (LV-1101), maintaining a
constant level of liquid propane. Propane vaporizes at

0∘C and 4.8 Kg/cm2a pressure in the chiller.

 Compression: Vaporized propane from the chiller goes to the suction

of reciprocating propane compressors (K-501 A/B) via a suction
KO drum (V-501) where traces of liquid propane are removed. The
compressors are single-stage reciprocating type and compress propane
to

16 Kg/cm2a pressure. One compressor operates, and one is standby.

 Condensation: Compressed propane is then condensed at 45∘C in the

propane condenser (E-503) by circulating cooling water. Condensed
propane goes to the

accumulator (V-502) for reuse.

 Pressure Control & Temperature Maintenance: Suction pressure

control prevents chiller pressure from dropping below 4.8 Kg/cm2a
(corresponding to 0∘C evaporation temperature). Hot compressor
bypass propane gas is cooled by spraying liquid propane in a

mixing nozzle (X-502) to maintain compressor suction temperature at

0∘C.

 Major Equipment and Types:

 o Gas-Gas Exchangers (E-501 A/B/C/D): Heat exchangers.
o Gas Chiller (E-502): Heat exchanger, uses propane refrigerant.
o Filter-Separator (X-501): Filter-separator.
o Propane Sub-Cooler (E-504): Heat exchanger.
o Suction KO Drum (V-501): Knock-out drum/Vessel.
o Reciprocating Propane Compressor (K-501 A/B): Compressor, single stage
reciprocating type.
o Propane Condenser (E-503): Heat exchanger.
o Accumulator (V-502): Vessel/Accumulator.
o Mixing Nozzle (X-502): Nozzle.
o Pumps: Condensate transfer pumps (P-501 A/B).

5. Sulphur Recovery Unit (SRU)

The SRU converts hydrogen sulfide (H2S) from the acid gas into elemental sulfur, making it
environmentally safe. The Hazira Plant has 6 SRU trains and one incinerator.

 Process in Detail:
o Acid Gas Feed: The SRU receives acid gas from the GSU, with an H2S
concentration ranging from 0.3 to 5.2 mole percent (3000 to 52000 ppm).
Each train can treat up to

7000 Nm3/hr of acid gas. Acid gas properties: Pressure

0.8−1.0 kg/cm2, Temperature 45−50∘C.

o Feed Gas Knock-Out Drum: Acid gas enters Unit 61 through a flow control
valve and into a feed gas knock-out drum, which removes any condensate.
This condensate is removed and sent to the MDEA Sump Storage tank (60-V-
654).
o LO-CAT Process (Absorption & Oxidation): The core of the SRU is the
Absorber/Oxidizer (61-V-602), which uses the LO-CAT process.
 Absorption: Sour gas is introduced into the absorber section's center
well, where it contacts a basic solution of ARI-310 catalytic reagent.
The

H2S is absorbed and converted to elemental sulfur.

 Sulphur Settling: The newly formed solid sulfur particles, being

approximately twice the density of water, settle down into the settler
(cone) section of the vessel.
 Catalyst Regeneration: The "reduced" catalyst solution (containing
Fe+2) from the absorber underflows into the oxidizer section. Here, it
is regenerated by contact with air (supplied via air blast sparger ring) ,
which also provides the driving force for circulating the LO-CAT
solution by lowering the bulk density of the oxidizing section.
Regenerated solution spills over the top wall of the absorber center
wells, completing the oxidation/regeneration cycle.
  Water Make-up: Demineralized water is added on flow control
(61FIC-1204), reset by level (61-LIC-1204), to the absorber/oxidizer
or the recirculating sulphur slurry line to account for net water loss.
o Sulphur Withdrawal and Filtration (AVPF): Sulphur is continuously
withdrawn from the bottom cone of the settler section and pumped by mono
type progressive cavity positive displacement pumps to the Automated
Vertical Pressure Filter (AVPF).
 AVPF Batch Process: The AVPF operates in consecutive cycles:
1. Feeding: Slurry from a surge tank (V-604/605) is pumped to
the AVPF until a required pressure of 5 kg/cm2g is achieved.
2. Pre-squeezing: DM water is pumped to maintain squeezing
pressure, with filtrate outlet ABVs remaining open.
3. Cake Wash: Cake wash water is recirculated through the filter
for a set time.
4. Final Squeezing: DM water is pumped at a higher pressure
(16 kg/cm2g) for 10-15 minutes to further squeeze the cake.
5. Air Purging: Plant air passes through the cake and filter cloth
for a set time to remove remaining moisture.
6. Cake Discharge/Cloth Wash: Cylinders are lowered, plates
open for cake discharge into screw conveyors (60-LZ-601
A/B). Simultaneously, the filter cloth is washed.
o Sulphur Storage: Liquid sulphur exiting the separator flows to the sulphur
surge tank (61-V-604), which has about 7 days of storage capacity. The
product sulfur has a purity of 99.9%.
o Incinerator: If SRU trains malfunction or are under maintenance, acid gas is
automatically diverted to a standby thermal incinerator (Tr. 60). The
incinerator is designed for a maximum of

7000 Nm3/Hr and oxidizes hydrogen sulfide and hydrocarbons before

expelling them.

o Chemical Requirements: Regular make-up of ARI-310M, ARI-310C, KOH,

Surfactant, and Biochem is required to maintain the LO-CAT solution's
chemical composition. KOH solution maintains the required pH for

H2S absorption.

 Major Equipment and Types:

o Feed Gas Knock Out Drum: Knock-out drum/Vessel.
o Absorber/Oxidizer (61-V-602): Combined column/vessel.
o Sulphur Surge Tank (61-V-604): Storage tank.
o Automated Vertical Pressure Filter (AVPF): Filtration system.
o Incinerator (Tr. 60): Vertical cylindrical furnace with one burner.
o Pumps: Mono type progressive cavity positive displacement pumps , slurry
feed pump , squeezing water pump (P613A/B, P614A/B) , cake wash water
pump (P-606 A/B, P-607 A/B) , cloth wash water pumps.
o Tanks: T-603 A/B (DM water) , T-602 A/B (cake wash water) , T-604 A/B
(cloth wash water).

6. Condensate Fractionation Unit (CFU)

The CFU sweetens the condensate by removing dissolved H2S and recovers valuable
products like LPG and NGL. There are seven CFU trains, with a design capacity of

51.5 tons/hr or 75 m3/hr of sour condensate.

 Process in Detail:
o Condensate Receiving System:
 Preheating: Condensate from the slug catcher is heated in a
condensate preheater using LP steam to 33∘C−36∘C to prevent
hydrate formation due to potential high pressure drops across valves.
 Surge Drum: The preheated condensate is received in a surge drum
under level control. Flash vapor from the surge drum is either taken to
the GSU directly (if condensate inlet pressure is

≥80 kg/cm2) or routed through a compressor system (if pressure is

<80 kg/cm2). Any free water droplets are separated and collected in a
boot, drained via interface level control.

 Pumping & Filtering: Condensate is taken by transfer pumps to

generate sufficient head to avoid flashing in the downstream filter
coalescer. Two cartridge-type

filter-coalescer units (one operating, one standby) filter out scale,

dust, debris, iron sulphides, and black material, and remove free water.

 Stripper Column Feed: The condensate then flows through a flow

control valve into the stripper column top tray. This maintains back
pressure to prevent flashing in the filter chamber. Condensate from
DPD units can also be processed here.
o Fractionation:
 Stripper Column: Lighter fractions (offset gas) come out from the top
of the stripper column, go into a knockout drum where liquid is
separated, and then to the GSU. LPG components move into a

reboiler, from where they are refluxed back into the stripper column
for purification. The stripper's temperature is maintained by HP steam.

LPG Production: Some purified liquid goes to the LPG Line.

NGL & Naphtha Production: From the bottom of the stripper
column, Naphtha and NGL are produced. This NGL either goes to the
Kerosene Recovery Unit (KRU) or the NGL line depending on
consumer demand.
 Caustic Washing: LPG from the reboiler section undergoes caustic
washing to remove H2S.
 Major Equipment and Types:
o Condensate Preheater: Heat exchanger.
o Surge Drum: Surge drum/Vessel.
o Filter-Coalescer: Cartridge type filter-coalescer.
o Stripper Column: Column.
o LPG Column: Column.
 o Reflux Drum: Vessel.
o Thermo-Siphon Reboiler: Reboiler.
o NGL Cooler: Heat exchanger.
o Pumps: Condensate transfer pumps.
o Knockout drum: Vessel.

7. Caustic Wash Unit (CWU)

The CWU removes residual

H2S from sour LPG, ensuring it meets purity specifications before storage. It can remove up
to 100 ppm of

H2S from sour LPG.

 Process in Detail:
o Caustic Solution Preparation: Fresh caustic solution (48-50%) is diluted
with DM water to prepare the desired 10 wt/wt% solution in conical roof
tanks.
o LPG Washing: Sour LPG from the CFU, containing H2S (20-80 ppm) , is
washed with the caustic solution in

Caustic Wash Drums. The

H2S reacts with NaOH to form NaHS and Na2S.

o Sweet LPG Storage: The sweet LPG, now containing less than 5 ppm H2S ,
is routed to LPG spheres for storage.
o Capacity: The system consists of 5 identical trains, each handling 40 m3/hr of
sour LPG. Normally, 4 trains operate, with one standby.
 Major Equipment and Types:
o Caustic Wash Drums: Contact vessels/columns.
o Caustic Storage Tanks: Conical roof tanks.
o Caustic Pumps: Pumps, 10 m3/hr each, used for unloading and solution
transfer.

8. NGL Fractionating Unit (NFU) / Kerosene Recovery Unit (KRU)

These units process NGL (Natural Gas Liquid) to produce value-added products like
Naphtha, Kerosene, HSD, and potentially ATF. The design capacity of KRU is 1.5 MMTPA
(

189.39 M.T./hour) of NGL from CFU trains.

 Process in Detail:
o NGL Feed Handling: NGL from CFU trains (71-77) is received at 150∘C and
5.2 kg/cm2a pressure. It's initially taken into a
 feed surge drum (90 - V 901) operating at 4.5 kg/cm2a and 135∘C. A back
pressure control valve (PV-1106) prevents excessive flashing. The present
processing capacity is

6600 m3/day.

o Pre-treatment: The NGL is then pumped into a feed coalescer to remove any
foreign particles.
o Heating: It is sent to a column feed heater or furnace (H.901) to increase its
temperature to 210∘C. Burners in the furnace heat fuel gas, which then
exchanges heat with the NGL feed.
o Primary Fractionation (Naphtha Column): The heated feed enters Column
1 (Naphtha Column, C-901) where value-added products are separated based
on controlled pressures and temperatures.
 Aromatic Rich Naphtha (ARN) is obtained from the top.
 A mixture of Superior Kerosene Oil (SKO) and High-Speed Diesel
(HSD) is obtained from the middle.
 Low Sulphur Heavy Stock (LSHS) is obtained from the bottom.
o Secondary Fractionation (SKO/HSD Separation): The SKO and HSD
mixture is sent to stripping columns.
 In the first stripping column, light ends are stripped to ARN, and the
bottom part is SKO.
 In the second stripping column, light ends are stripped to SKO, and the
bottom part contains HSD.
o ATF Production (Optional): If ATF (Aviation Turbine Fuel) is to be
produced, the unit operates in a different mode, requiring precise control of
physical parameters like temperature and density. Some SKO can be sent to

polishing units to modify its properties for ATF production.

o Product Handling: All products obtained from these columns are sent to
surge drums for temperature and flow rate maintenance. Water, if present, is
separated in the surge drum (Oil Water Sewage - OWS process). Products are
then cooled using

air or water cooling and transferred to final storage tanks.

 Major Equipment and Types:

o Feed Surge Drum (90 - V 901): Surge drum/Vessel.
o Feed Coalescer: Coalescer/Filter.
o Column Feed Heater/Furnace (H.901): Furnace/Heater.
o Naphtha Column (C-901): Distillation column.
o Kerosene/ATF Column (C-902): Distillation column.
o Stripping Columns: Distillation columns.
o Surge Drums (for products): Vessels.
o Coolers: Heat exchangers (air cooling or water cooling).
o ATF Polishing Units: Includes Caustic Wash , Settler , Water Wash , Rock
Salt , Clay Filters , Filters.
o Pumps: ATF Pump , ATF dispatch Pump.
o Reboilers (e.g., E912, H.901, H.902): Heat exchangers.
 o Condensers (e.g., E903, E905): Heat exchangers.
o Reflux Drums (e.g., V-902, V-903): Vessels.

9. Liquefied Petroleum Gas (LPG) Unit

The LPG recovery plant processes sweet gas and associated condensate from DPD units to
extract LPG, with a capacity of 5 MMSCMD of sweet gas.

 Process in Detail:
o Feed Gas Pre-treatment: Sweet gas from the GSU (75−52 Kg/cm2abs,
around 38∘C) flows to a Knock Out Drum to remove any liquid. Bulk water
is removed by cooling the gas to

25∘C (presently 22−24∘C).

o Gas Drying: The gas then flows through molecular sieve dryers, reducing
moisture to less than 1 PPM. One dryer operates while the other is
regenerating.
o Cryogenic Chilling: Dried gas is cooled to −30∘C in a Cold Box (E-101) (a
brazed aluminium plate fin exchanger). Condensed liquid is separated in

Separator-I (V-102).

o Expansion & Further Cooling: Vapors from Separator-I are isentropically

expanded in the expander section of the Expander-Compressor (EK-
101A/B), further lowering the temperature to −54∘C (presently around
−53.6∘C). Liquid condensed is separated in

Separator-II (V-103).

o Lean Gas Compression: Refrigeration from the vapor stream of Separator-II

is recovered to cool the feed gas. This lean gas is then compressed by the
expander compressor to about

37 Kg/cm2abs (from 30 kg/cm2) and finally to 48.5 Kg/cm2abs (presently

46.5 Kg/cm2abs) by the lean gas compressor, supplied to consumers as high-
pressure lean gas.

o Condensate Processing: Condensate from the DPD unit (73−50 Kg/cm2abs

pressure, 60 Kg/cm2abs at present) is flashed into a surge drum after heating
(25∘C−30∘C presently) to avoid hydrate formation. It passes through a

Coalescer to separate free water. Hydrocarbon liquid from the Coalescer

flows to

liquid dryers, reducing moisture to 5 ppm.

o Light Ends Fractionation (LEF): Liquid from Separator-I & II, along with
liquid from the liquid dryer outlet, is routed to the Light Ends Fractionation
 (LEF) Column (C-101). Methane, ethane, part of propane, and most of
carbon dioxide are removed as overhead product.
 LEF Overhead Condensation: Overhead vapors are condensed in the
LEF Condenser (E-106) to about −19.2∘C (presently, −23∘C to
−24∘C) using propane refrigerant.
 LEF Reboiler: Reboil heat is provided by a kettle type Reboiler (E-
107), using LP steam (from cogeneration).
 LEF Overhead Gas Utilization: LEF overhead gases are expanded in
an expander to recover refrigeration and cool the feed gas. These gases
are then compressed for supply to KRIBHCO as Low-pressure lean gas
and for internal fuel gas consumption. Excess gas is compressed to the
high-pressure lean gas header.
o LPG Column: Liquid from the bottom of the LEF column is fed to the LPG
Column (C-102) (2M O.D., about 37.4 m height, with 54 valve trays) for
separation of LPG and aromatic rich naphtha (ARN).
 LPG Product: LPG is withdrawn as the column top product and sent
to storage. Vapour pressure of LPG =

16.87 Kg/cm2a (max) at 45∘C.

H2S is maintained less than 4ppm.

 ARN Product: ARN is withdrawn as the column bottom product and

sent to storage via the Aromatic Rich Naphtha Cooler (E-110),
which cools the stream to 45∘C. ARN Vapour pressure =

0.9 Kg/cm2a (max) at 40∘C.

o Propane Column: A small part of the LPG product is sent to the Propane
Column (1.2 m O.D., about 25.5 m tall, with 35 one-pass valve trays) for
fractionation to produce pure propane, used as a refrigerant for the LEF
overhead condenser.
 Operation: Operates at a top temperature of 48.3∘C (presently 42∘C)
and a bottom temperature of 79.25∘C (presently 69.0∘C at
13.5 kg/cm2g). Vapors are condensed in a

water-cooled condenser (Propane Column condenser), and

condensed liquid is collected in the reflux drum. Pressure control
(PIC-1101) manages cooling water flow to the condenser or flaring
from the reflux drum. Propane column bottom product is sent to LPG
storage after cooling in the

Propane Column Bottom Cooler (E-113) to 45∘C.

 Major Equipment and Types:

o Knock Out Drum: Vessel.
o Molecular Sieve Dryer (Gas Dryers): Adsorption dryer.
o Cold Box (E-101): Brazed aluminium plate fin exchanger.
o Separator-I (V-102): Separator/Vessel.
o Expander-Compressor (EK-101A/B): Turboexpander-compressor.
 o Separator-II (V-103): Separator/Vessel.
o Lean Gas Compressor: Compressor.
o Surge Drum (for DPD condensate): Surge drum/Vessel.
o Coalescer (for DPD condensate): Coalescer.
o Liquid Dryers: Dryer.
o Light Ends Fractionation (LEF) Column (C-101): Tray column.
o LEF Condenser (E-106): Partial condenser, water-cooled condenser.
o Reboiler (E-107): Kettle type reboiler.
o LPG Column (C-102): Tray column, 54 valve trays.
o LPG Column Condenser (E-108): Condenser.
o LPG Column Reflux Drum: Reflux drum/Vessel.
o Aromatic Rich Naphtha Cooler (E-110): Cooler/Heat exchanger.
o Propane Column: Tray column, 35 one-pass valve trays.
o Propane Column Condenser: Water-cooled condenser.
o Reflux Drum (for Propane Column): Reflux drum/Vessel.
o Propane Column Bottom Cooler (E-113): Cooler/Heat exchanger.
o Propane Column Condensate Pot: Vessel.

10. Offsite and Utilities

Offsite facilities and utility systems provide essential support services for the entire Hazira
plant's operation, though they may not directly contribute to revenue.

 Storage Facilities: Various products are temporarily stored in different types of tanks
and spheres:
o LPG Storage Spheres (Horton Spheres): Spherical tanks for pressurized gas
storage. 9 spheres total,

22500 m3 capacity. Safely filled to

2100 m3 but currently used for 1200 m3 storage at 8.5 kg/cm2 pressure. Ethyl
mercaptan is mixed for leak detection.

o Naphtha Storage Tanks: Floating Roof Tanks for volatile liquids. 8 tanks,

9900 m3 capacity.

o NGL Storage Tank: 2 tanks, 33000 m3 capacity.

o Kerosene Storage Tank: 4 tanks, 20000 m3 capacity.
o HSD/ATF Storage Tank: 2 tanks, 2000 m3 capacity.
o Heavy Cut/HSD Tank: 3 tanks, 6000 m3 capacity.
o Propane Storage Sphere: 1 sphere, 311 m3 capacity.
o Raw Water Reservoir: 4 reservoirs, 8 lakh m3 capacity. Raw water systems
have an operating capacity of about

2000 m3/hr (5 pumps x 750 m3/hr, 2 standby).

 Cogeneration Plant (COGEN): Provides in-house electricity and steam generation.

o Process in Detail:
  Electricity Generation: LP gas (0.7-0.8 MMT daily usage) is
compressed by a Compressor and sent to a Combustion Chamber.
The hot gases (at

1200∘C) drive Gas Turbines to produce electricity (57.6 MW total

from 3 gas turbines).

 Steam Generation (HRSG): Exhaust gases from the gas turbines are
used to heat water in a Heat Recovery Steam Generator (HRSG) to
produce steam (HP and LP steam). A special flap releases exhaust if
heating is not required.
 Steam Turbine (not present, per report): The report indicates no
steam turbine, meaning generated steam is directly supplied to the
Hazira plant.
 Combined Cycle Efficiency: A combined cycle efficiency of about
55% is achieved.
 Control & Monitoring: The unit is controlled and monitored from a
control room with special panels.
 Demineralized (DM) Water Plant: Produces DM water by removing mineral ions
from raw water using ion exchange resins. DM water is used to generate steam.
o Process in Detail: Raw water passes through an Activated Carbon Filter,
then Strong Acid Cationic Exchanger, a Degasser, Weak Base Anionic
Exchanger, Strong Base Anionic Exchanger, and finally a Mixed Bed
Exchanger to produce demineralized water. HCl and NaOH are used for
regeneration/injection. Raw water treatment plant capacity:

48000 m3/day.

 Waste Water Treatment Plant (WWTP): Handles 50 m3/hr of effluent to meet

Minimum National Standards (MINAS).
o Process in Detail:
 Collection & Equalization: Total wastewater (715 m3/day dry
weather flow) is collected in dry weather sump (100-S-01). During
dry weather, effluent is pumped at

30 m3/hr to equalization tanks. During monsoon, excess flow

overflows to a

wet weather sump (100-S-02) and is pumped to the 'On-stream'

equalization tank.

 Oil Separation: A constant flow (25 m3/hr) is taken to a Cross Flow

Interceptor unit to remove free oil.
 Chemical Treatment: Effluent from the interceptor is fed to a
chemical treatment section (flash mixer and CPF/TPF Microflotator
- DAF) to handle emulsified oil and suspended solids, using alum as a
coagulant. Skimmed floating matter goes to chemical sludge sump,
slop oil to slop oil tanks.
 Biological Treatment: Water free from impurities is fed into the
biological treatment unit (extended aeration type activated sludge
 process) to remove BOD, COD, and phenols. Oxygen is supplied by
two 7.5 HP

mechanical fixed type surface aerators. Nutrients (urea, phosphoric

acid) are added at the inlet of aeration tank.

 Final Clarifier & Tertiary Treatment: A final clarifier separates

biological solids. The effluent undergoes tertiary treatment through

pressure sand filters followed by activated carbon filters.

Backwash sump and pumps are provided for backwashing. A bypass

line can return effluent to the equalization tank if it doesn't meet
quality.

 Final Polishing: The treated effluent passes through a Guard Pond

(100-T-08) for final polishing before disposal.
 Sludge Management: Excess biological sludge goes to a thickener.
Thickened sludge is pumped to a

centrifuge (currently to sludge drying beds). Polyelectrolyte dosing

facilities are provided for centrifuge and CPF unit.

o Waste Water Systems: The plant has separate systems for Process Waste
(PWS) , Oily Water System (OWS) , Sanitary Sewage (SS) , Storm Water
Drainage , Spent Locat , and Spent Caustic.
 Air Systems: Include Instrument Air (moisture-free for instruments) and

Plant Air (may contain moisture, used in SRU).

 Inert Gas (IG) Plant: Generates nitrogen from atmospheric air using Pressure
Swing Adsorption (PSA) for purging during shutdown and startup activities, and as a
sealing medium in specific pumps. Nitrogen requirement is approximately

400 m3/hr.