Process Flow Description
● Very Dirty Oil ISO Tank (T-101) → Compabloc Heat Exchanger (E-101)
Connection: From bottom nozzle N-101 of T-101 to suction of Pump P-101.
Pump: P-101 (Progressive Cavity Pump) – Handles viscous feed, provides steady positive
displacement flow.
Valves:
● V-101 – Suction isolation valve (maintenance)
● V-102 – Discharge isolation valve (flow stop)
● V-103 – NRV (prevents backflow to tank)
Flow Path: Pump discharge to inlet of Compabloc HE (E-101).
Purpose: Preheats very dirty oil to 60–80 °C to reduce viscosity and improve separation.
● Compabloc Heat Exchanger (E-101) → Decanter (D-101)
Connection: Outlet nozzle N-102 of E-101 to top feed nozzle N-201 of Decanter.
Pump: Not required (gravity flow due to height difference).
Valves:
● V-104 – Outlet isolation valve on HE
● V-105 – Inlet isolation valve on Decanter
Flow Path: Heated oil flows into Decanter.
Purpose: Separates oil phase and water phase.
● Decanter (D-101) → Oil-Water Separator (W-101)
Connection: Water outlet nozzle N-202 of Decanter to suction of Pump P-102.
Pump: P-102 (Centrifugal Pump) – Transfers separated water to oil-water separator.
Valves:
● V-106 – Suction isolation
● V-107 – Discharge isolation
● V-108 – NRV
Flow Path: Water-rich stream flows to oil-water separator.
Purpose: Further separates residual oil from water.
● Oil-Water Separator (W-101) → Water Tank (T-102)
Connection: Water outlet nozzle N-301 of W-101 to Tank T-102.
Pump: Not required (gravity flow).
Valves: V-109 – Outlet isolation valve.
Flow Path: Clean water collected in Water Tank.
Purpose: Provides feed water for scrubber circulation.
● Decanter (D-101) → Not So Dirty Oil Tank (T-103)
Connection: Oil outlet nozzle N-203 of Decanter to suction of Pump P-103.
Pump: P-103 (Centrifugal Pump).
Valves:
● V-110 – Suction isolation
● V-111 – Discharge isolation
● V-112 – NRV
Flow Path: Oil from Decanter to Not So Dirty Oil Tank.
Purpose: Stores partially cleaned oil before furnace heating.
● Not So Dirty Oil Tank (T-103) → Furnace (F-101)
Connection: From bottom nozzle N-401 of T-103 to suction of Pump P-104.
Pump: P-104 (Progressive Cavity Pump) – Suitable for moderately viscous oil.
Valves:
● V-113 – Suction isolation
● V-114 – Discharge isolation
● V-115 – NRV
Flow Path: Oil fed to Furnace (F-101).
Purpose: Oil heated to 100–120 °C, moisture removed.
● Furnace (F-101) → Preheater (E-102)
Connection: Furnace outlet nozzle N-402 to Preheater inlet nozzle N-501.
Pump: Not required (pressure-driven).
Valves:
● V-116 – Outlet isolation
● V-117 – Inlet isolation
Flow Path: Heated oil passed to Preheater. Furnace flue gases used as utility for heating.
Purpose: Raises oil temperature further for distillation.
● Preheater (E-102) → Distillation Reactor (R-101)
Connection: Outlet nozzle N-502 of Preheater to mid-section feed nozzle N-601 of Reactor.
Pump: Not required.
Valves:
● V-118 – Outlet isolation
● V-119 – Inlet isolation
Flow Path: Preheated oil enters reactor.
Purpose: Feed introduced into reactor under vacuum conditions.
● Distillation Reactor (R-101) → Primary Catalytic Tower (C-101)
Connection: Vapor outlet nozzle N-602 at top of Reactor to bottom feed nozzle N-701 of
Primary Catalytic Tower.
Pump: Not required (vacuum-driven flow).
Valves:
● V-120 – Outlet isolation
● V-121 – Inlet isolation
Flow Path: Vaporized hydrocarbons passed to Primary Catalytic Tower.
Purpose: Catalytic cracking and upgrading of vapors. Reactor operates at 400–450 °C
under vacuum.
● Primary Catalytic Tower (C-101) → Secondary Catalytic Tower (C-102)
Connection: Vapor outlet nozzle N-702 at top of C-101 to bottom feed nozzle N-801 of C-102.
Valves: V-122 outlet isolation, V-123 inlet isolation.
Flow Path: Vapors move sequentially for secondary catalytic treatment.
Purpose: Further cracking, removal of heavier fractions.
● Secondary Catalytic Tower (C-102) → Fractionator Column (FRC-101)
Connection: Vapor outlet nozzle N-802 at top of C-102 to feed nozzle N-901 of Fractionator
Column.
Valves: V-124 outlet, V-125 inlet.
Flow Path: Vapors enter fractionation section.
Purpose: Fractionation under vacuum to separate diesel, light fractions.
● Fractionator Column (FRC-101) → Diesel Condenser (CD-101)
Connection: Bottom vapor outlet nozzle N-902 to Diesel Condenser inlet N-1001.
Valves: V-126 outlet, V-127 inlet.
Flow Path: Heavier vapors condensed as Diesel.
Purpose: Produces liquid diesel fraction.
● Diesel Condenser (CD-101) → Diesel Storage Tank (T-104) → ISO Tank
Connection: Bottom nozzle N-1002 of Diesel Condenser to Diesel Tank suction of Pump P-105.
Pump: P-105 (Centrifugal Pump).
Valves:
● V-128 suction
● V-129 discharge
● V-130 NRV
Flow Path: Diesel collected in Tank and pumped to ISO Tank.
Purpose: Final product storage and dispatch.
● Fractionator Column (FRC-101) → Light Fraction Condenser (CD-102)
Connection: Top vapor outlet nozzle N-903 to Condenser inlet N-1101.
Valves: V-131 outlet, V-132 inlet.
Flow Path: Light vapors condensed.
Purpose: Light fraction separation.
● Light Fraction Condenser (CD-102) → Light Fraction Tank (T-105) → ISO Tank
Connection: Bottom nozzle N-1102 to Tank T-105 via Pump P-106.
Pump: P-106 (Centrifugal Pump).
Valves:
● V-133 suction
● V-134 discharge
● V-135 NRV
Flow Path: Light fraction collected and pumped to ISO Tank.
Purpose: Final storage and dispatch.
● Water Vapour Condensation via 3-Stage Condenser
Connection: Water vapor from Preheater overhead passed through 3-stage condenser.
Valves: V-136 isolation valves per stage.
Flow Path: Water vapors condensed into liquid water.
Purpose: Efficient removal of water vapors before vacuum system.
● Sludge Handling
Connection: Sludge outlet nozzles from reactor and towers to Sludge Tank (T-106).
Pump: P-107 (Progressive Cavity Pump) for sludge transfer.
Valves: V-137 suction, V-138 discharge, V-139 NRV.
Flow Path: Sludge collected and recycled to reactor if oil present.
Purpose: Reduces oil loss, handles heavy residues.
● Scrubber Unit (S-101) → Cyclone Separator (CY-101) → Water Tank (T-102)
Connection: From Water Tank T-102 → Pump P-108 → NaOH Doser → Scrubber inlet→
cyclone separator → Water loop back to Water Tank.
From the bottom nozzle of Scrubber S-101 (N-202), the scrubbing liquid flows to Cyclone
Separator CY-101, where entrained liquid droplets are removed. A centrifugal pump (P-108)
recirculates the water back to Tank T-102. Valves V-1201 (isolation) and V-1202 (relief) ensure
safe and reliable operation of this line.
● Scrubber Gas Outlet S-101 → Chimney
Gas outlet from Scrubber → cleaned gas vented to chimney
From the top nozzle of Scrubber S-101 (N-201), treated gases exit and are directed to the plant
chimney. A vent valve (V-1301) is provided for controlled release, along with necessary safety
measures for pressure equalization.
● Vacuum System
Connection: Fractionator overhead non-condensables → Knock-Out Drum (V-201) → Liquid
Ring Vacuum Pump (P-109) → Vent.
Valves: Isolation valves, safety relief valve on KO Drum.
Purpose: Maintains ~0.1 MPa vacuum in system, removes non-condensables.
