SUMMER TRAINING REPORT

INDIAN OIL COPORATION LIMITED

PANIPAT
Under the supervision of
RAKESH KUMAR(PNM)
“Overview of DHDT and HGU unit and to find the efficiency of Boiler”

By

ADARSH RAI (2020UCH1275)

BACHELOR OF TECHNOLOGY(B. TECH) IN CHEMICAL ENGINEERING

MALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY,

JAIPUR
(Duration: 15th May, 2023 to 26th June, 2023)

Submitted To: Submitted By:

Mr. Pankaj Tripathi Adarsh Rai

Head L&D Centre. VT CH-056

IOCL, Panipat.
 PREFACE

Industrial training is critical to the advancement of future engineers. It not only

provides insights in to the future, but it also bridges the gap between theory and
practical knowledge. I was fortunate to be given the opportunity to receive
industrial training at INDIAN OIL CORPORATION LTD. PANIPAT, one of
India’s premier refineries.

The experience gained during this brief period was fascinating. It was an
incredible feeling to observe the operation of various units and processes. It was
overwhelming for us to see how such a large refinery is monitored and operated
in a coordinated manner to achieve the desired results.

During my training, I realized that in order to be a successful chemical engineer,

one must apply his or her concepts. As a result, I hope that this training will
serve as a stepping stone for me in future, allowing me to carve out a niche for
myself in this field.
 ACKNOWLEDGEMENT

It is great that Indian Oil Corporation Limited provides training to a

large number of students like us for practical assimilation of
knowledge pertaining to our respective disciplines. After the
compeletion of the training program, I found it to be of immense help,
not only in supplementing the theoretical knowledge, but also by
gaining highly practical knowledge the actual work carried out in
refinery plant.
I express my deep and sincere gratitude to Mr. Pankaj Tripathi (Sr.
Officer, Training & Development) who provided me with the
opportunity to get practical training in Indian Oil Corporation
Limited, Panipat.
I also acknowledge my deep obligation to Mr. Rakesh Kumar
(Production Manager) and all officers of CR 11 for their kind
behavior, constant support and motivation and valuable knowledge
imparted to me during my training period.
 INDEX

SR. NO. TOPIC

1. Introduction – Indian Oil

2. Introduction – Panipat Refinery

3. Introduction -DHDT

4. Flow diagram - DHDT

5. Process Description

6. Introduction – HGU BS VI

7. Flow diagram – HGU

8. Process Description

9. Project on Boiler

10. Conclusion
 INDIAN OIL

Indian Oil Corporation Limited (IOCL) is an Indian central public

sector undertaking under the ownership of the Ministry of Petroleum
and Natural Gas, Government of India. It is headquartered in New
Delhi. It is a public sector undertaking whose operations are overseen
by the Ministry of Petroleum and Natural Gas. Indian Oil is ranked
142nd on the Fortune Global 500 list of the world's biggest
corporations as of 2022. It is the largest government owned oil
producer in the country both in terms of capacity and revenue. It has
consolidated refining capacity of 80.55MMTPA which it intends to
increase to 107MMTPA by 2024-25. As of 31 March 2021, Indian
Oil's employee strength is 31,648, out of which 17,762 are executives
and 13,876 non-executives, while 2,776 are women, comprising
8.77% of the total workforce.

Indian Oil's business interests overlap the entire hydrocarbon value

chain, including refining, pipeline transportation, marketing
of petroleum products, exploration and production of crude
oil, natural gas and petrochemicals. Indian Oil has ventured
into alternative energy and globalisation of downstream operations. It
has subsidiaries in Sri Lanka (Lanka IOC), Mauritius (IOC Mauritius
Ltd) and the Middle East (IOC Middle East).
Objective:
 To serve national interests in oil and other sectors in accordance
and consistence with government policies.
 To ensure maintenance of continuous and smooth supplies of
petroleum products by way of crude refining, transportation and
marketing activities and to provide appropriate assistance to
conserve and use petroleum products efficiently.
 To enhance the country’s self-sufficiency in crude oil refining
and building expertise in laying of crude oil and petroleum
product pipelines.

Refineries of IOCL in India:

 Panipat - 15 MMTPA
 Mathura - 8 MMTPA
 Barauni - 6 MMTPA
 Gujarat - 13.7 MMTPA
 Guwahati - 1 MMTPA
 Digboi - 0.65 MMTPA
 Haldia - 7.5 MMTPA
 Bongaigaon - 2.35 MMTPA
 Paradip - 15 MMTPA
Products of IOCL:
 Indian Gas
 Auto Gas
 Petrol/ Gasoline
 Diesel/ Gas oil
 ATF/ Jet fuel
 Servo lubricants & greases
 Marine fuel & Lubricant
 Kerosene
 Bulk/ Industrial Fuel
 Bitumen
 Petrochemicals
 Special product
 Benzene
 CBFS
 Food gate hexane
 Jute batching oil
 Micro crystalline wax oil
 Mineral turpentine oil
 Paraffin wax
 Propylene
 Raw petroleum coke
 Sulphur
 Toluene
 PANIPAT REFINERY

Panipat Refinery has doubled its refining capacity from 6MMTPA to

12MMTPA with the commissioning of its expansion project. Panipat
refinery is the seventh refinery of Indian Oil. It is located in the
historic district of Panipat in Haryana and it is about 23 km away
from Panipat city. The original refinery with 6MMTPA was built and
commissioned in 1998 at the cost of Rs. 3868.

The major secondary processing units of refinery include catalytic

reforming unit , once through hydrocracker, residue fluidized catalytic
cracking unit, vis breaker unit, bitumen blowing unit, Sulphur block
and associated auxiliary facilities. In order to improve diesel quality a
diesel hydro-desulphurization unit (DHDS) was subsequently
commissioned in 1999.

Referred to as India’s most modern refineries, Panipat refinery was

built using global technologies from IFP France, Haldor – Topsoe,
Denmark, UOP, USA, and stone & webster , USA. It processes a wide
range of both indigeneous and imported grades of crude oil. It
receives crude from Vadinar through 1370 km long Salaya – Mathura
pipeline which also supplies crude to Koyali and Mathura refinery of
Indian oil. Petroleum products are transported through various modes
like rail, road as well as environment friendly pipelines. The refinery
caters to high consumption demand centers in north – western india
including the states of Punjab, Haryana, J&K, Himachal, Chandigarh,
Uttarakhand as well as parts of Rajasthan and Delhi.
The LPG product from the refinery is pumped through a dedicated
pipeline to Indian oil’s Kohat bottling plant where bottling and bulk
dispatches are done. Panipat refinery has also developed new products
like 96 RNO petrol and subzero diesel for Indian army. It is already
operating at 100% capacity for the last 4 years.

Products of Panipat refinery:

 Indian Gas
 Naphtha
 Petrol/ Gasoline
 Diesel/ Gas oil
 ATF
 Bitumen
 Coke
 Sulphur

Units of Expansion Project:

 AVU
 DHDT
 HGU
 HCU
 MSQ
 DCU
 Sulphur recovery unit with tail gas treating unit
 Amine recovery unit
 QUALITY POLICY
We are committed:
 To achieve customer delight through support of quality products
and exceed the expectations and needs of customers.
 To comply with the statutory & regulatory requirements related
to the products.
 To continually improve the effectiveness of Quality
Management Systems for higher productivity and cost
effectiveness.
 To upgrade systems, technology and skills for competitive edge.

ENVIRONMENTAL POLICY
We are committed to:
 Comply with and excel the applicable environmental law and
regulations and strive for prevention of pollution.
 Conserve natural resources through optimum usage. Optimize
energy and water consumption in refinery operations
 Strive for continual improvement in environmental performance
by minimizing impact on environment due to refinery operations
and sulphur dioxide emissions.
 Zero discharge of treated trade effluents
 Upgrade technology and skills for environmental upkeep
 Propagate environmental awareness among employees ,
contractors and interested parties.
 OHS POLICY
We are committed to:

 Maintain safe and healthy working environment with focus to

minimize risk as low as reasonably possible
 Improve safety and health performance through occupational
health and safety assessment series (OHSAS) by continual
improvement
 Comply with applicable OHMS legislation
 Document, implement and maintain OH&S system
 Create awareness of OH&S policy among all employees,
contractors and interested parties.
 BRIEF DESCRIPTION OF DHDT PLANT

DHDT: DIESEL HYDROTREATER UNIT

Panipat Refinery operates Two Crude & Vacuum Distillation Units,
each having a capacity of 7.5MMTPA. Total refining capacity is
15MMTPA. It also operates one Delayed Coker Unit and one Resid
Fluidized Catalytic Cracking Unit. DHDT unit is envisaged to
hydrotreat the diesel streams from these units.

The main purpose of DHDT is to blend is to hydrotreat a hot blend of

raw diesel streams in order to produce a hydrotreated diesel stream
characterized by a cetane number improvement of 10 units (Two
Reactor Operation) over unit feed cetane and by a low sulphur
content(<30 ppm wt) while meeting the diesel product stability
specification of 1.6mg/100 ml. Cetane improvement is primarily
achieved by saturation reactions.

The unit capacity is 3.5MMTPA with an stream factor of 8000 hrs per
year. The original unit design allows a minimum continuous operating
cycle of 2 years meeting all product specifications at design.
HHPS: Hot high pressure separator
CHPS: Cold high pressure separator
CLPS: Cold low pressure separator
 PROCESS DESCRIPTION
The liquid feed to DHDT unit consists of SRGO, TCO and CGO
streams supplied from the battery limits. This gas oil blend flows to
the feed surge drum through feed filter. The oil is then pumped to the
reactor circuit using the reactor feed pumps.

Make-up hydrogen is supplied to the make-up compressor and is then

compressed by the makeup hydrogen compressor to the reaction
circuit pressure. The makeup and recycle gas streams are combined
with the liquid oil feed , and the total feed mixture is heat exchanged
against the reactor effluent in the reactor feed or effluent exchanger.
The preheated oil and hydrogen mixture is heated to the reactor inlet
temperature in the reactor feed heater. The total feed mixture is then
passed through hydrotreater reactors. The hydrotreater reactors
contain two reactors in series with each containing three catalyst bed.
Recycle hydrogen is used as the quench gas for maintaining the
desired WABT in each of the catalytic beds.

The reactor effluent is cooled by preheating the stripper feed in the

stripper feed preheater then by preheating the oil or hydrogen feed in
the feed or effluent exchanger. Additional cooling is obtained by heat
exchanging the effluent with the stripper field in the reactor effluent
or MP liquid exchanger in order to prevent any deposit of ammonium
salts.

The reactor effluent then is cooled in the reactor effluent air cooler
before being collected in the vertical HP cold separator drum. The
vapour phase from this drum consists of the recycle and quench gas
and is circulated by the recycles compressor. The hydrocarbon or
water separation obtained in this drum is not sharp, and hence both
the hydrocarbon rich and water rich streams are let down and once
again combined in the downstream MP cold separator for recovering a
hydrogen rich off-gas stream. Sour water is separated from the
hydrocarbon liquid phase and is routed to the battery limits. The
hydrogen liquid flows to the stripping section.
The recycle hydrogen stream leaving the HP cold separated drum is
routed to the HP amine absorber for H2S removal. The lean amine is a
40 wt% MDEA solution, supplied to the HP amine absorber using the
HP lean amine pumps. To prevent the possibility of foaming in the
absorber, the lean amine stream is first heated using LP steam in the
HP amine heater. The rich amine from the HP absorber bottoms is
sent to the LP amine absorber for flashing of the dissolved right ends.
The recycle gas leaving the HP amine absorber is then routed to the
recycle compressor through the recycle compressor drum. The H2
compressor discharge is split into recycle gas and quench gas streams
and the recycle gas is combined with the make-up hydrogen and gas
oil feed to enter reactor circuit. The quench gas flows to each reactor
bed.

The diesel stripper fractionates the diesel product from the reactor
effluent liquid stream, which is supplied from the MP cold separator
drum. The wild naphtha product from the stripper overhead is
stabilized and H2S stripped in the stabilizer liquid feed from the MP
separator is first preheated by heat exchange with the reactor effluent
in the reactor effluent or MP liquid exchanger and stripper bottoms in
the stripper feed/bottoms exchanger followed by the final heating in
heat exchange with the reactor effluent in the stripper feed preheater.
The hot feed enters the stripper and is stripped of H2S and light ends
using superheated MP stream to produce wet diesel product. The
stripper overhead vapor is condense in an air-cooled condenser and
the trim condenser. The off-gas product from the stripper reflux drum
is sent to the LP amine absorber. The water condensate containing
dissolved H2S and traces of NH3 is removed from the stripper reflux
drum water boot. This water is recycled to the water drum for water
injection upstream of the reactor effluent air cooler. The stripper flux
is returned to the tower and wild naphtha overhead product is sent to
the stabilizer.

The stripped wet diesel product is pumped to the battery limits. Heat
is recovered from the diesel product by preheating the stripper feed in
stripper feed or bottoms exchanger. The diesel product is further
cooled in the gas oil air cooler and gas oil trim cooler. The dissolved
water in the diesel product settles out as free water as the product
stream is cooled. The entrained water is removed in the the coalescer
and salt dryers before the diesel product is routed to the battery limits.

The wild naphtha product from the stripper overhead is combined

with the stripper naphtha from the DHDS unit, and the total naphtha
feed stabilized and H2S stripped in the stabilizer. This stabilizer feed
is preheated with the stabilizer bottom stream in the stabilizer
feed/bottom exchanger, and enter the stabilizer. The stabilizer is
reboiled using the hot diesel product from the stripper bottoms.
 BRIEF DESCRIPTION OF THE PLANT
HGU

SECTIONS IN UNIT

HGU consists of following sections:

1. Pre-Desulphurization section (PDS)

2. Hydrogen De-sulphuration (HDS)

3. Reforming

4. Shift section

The unit has been designed for operation on following feed:

 Straight run naphtha (SRN)

 Coker naphtha (maximum 27 tonnes per hour)

PROCESS FLOW DIAGRAM
 1. Pre - Desulphurization section (PDS)

The PDS is a primary processing step to remove bulk content of

sulphur in the SRN and coker naphtha feed which will contain
5900 wt ppm sulphur. However, this primary bulk removal does not
yield sufficient sulphur concentration in the feed to prevent poisoning
of the steam naphtha reforming catalysts, so a final desulphurization
is also required.
It consists of 2 reactors both loaded with catalyst. The main purpose
of the reactor is the removal of silica in the coker naphtha feed as this
is a potential poison for downstream catalysts. Catalyst will also
catalyze the conversion of di-olefins to mono-olefins and saturated
hydrocarbons.

2. Hydrogen - Desulphurization section (HDS)

The catalysts in HDS are extremely sensitive to sulphur compounds
since they cause deactivation or poisoning. Similarly, the MT shift
catalyst in the CO conversion section is also very sensitive to sulphur
and chlorine compounds.
It consists of 3 reactors, the 1st reactor is loaded with cobalt-
molybdenum oxide hydrogenation catalyst, the 2 nd section contains 2
reactors each containing both chloride absorption catalyst and zinc
oxide sulphur absorption catalyst.
 3. Reforming section
The gas from desulphurization section is mixed with steam and
sent to the reforming section where hydrocarbons are reacted
over nickel catalyst with steam.
The process gas is pre heated by heat exchange with hot flue gas
from the tubular reformer in the reformer feed pre heat coil
where most of the methane reforming takes place. The reaction is
strongly exothermic and heat of reaction is supplied indirectly by
firing.
TUBULAR REFORMING
The tubular reformer is constructed as two radiant chambers divided
into 5 sections. Each chamber contains a single row of 120
centrifugally cast tubes fabricated of high alloy Cr-Ni steel.

The original design tube wall temperature for this tube is 993 C. the
cold collector design temperature is 955C.
There are 240 tubes containing a total of 29.1 m3 reforming catalyst.
The process gas flows downwards with the gas entering the top of the
vertically mounted tubes from a header through “hairpins” at a
temperature of about 610 C -650 C depending on the plant load.
The gas leaves the tube at about 860 C and enters directly into a
refractory lined collector.
The tubes in the furnace are heated by total of 360 burners arranged in
6 rows on each side of the chambers to provide easy control of a
ubiform temperature profile along the length of the catalyst tubes.
Flue gas flow is upward with outlet near the top of the radiant
chamber. The flue gas outlet temperature is about 1045C - 1065C
depending on the feedstock used. Off -gas from the PSA units and
vaporised straight run naphthas are used as fuel for reformer and the
combustion air is supplied by the combustion air blower and is pre
heated to about 550C in the flue gas waste heat recovery section.

4. Flue Gas waste heat recovery section

The flue gas collector passes the flue gas from the radiant chamber to
the flue gas waste heat recovery section where the sensible heat of the
flue gas is used for :
In the waste heat recovery section the temperature of the flue gas is
decreased to about 160C and finally the flue gas leaving the waste
heat recovery section is passed to the stack by the flue gas fan.
The process gas leaving the tubular reformer passes through the waste
heat boiler producing saturated HP steam at 45kg/cm2g . The
temperature of the process gas is brought down to about 290 C. Then
the gas passes the first boiler feedwater pre heater which brings the
temperature down to 190C-210C. The optimal inlet temperature to
the MT shift converter is a function of the age of the catalyst and the
type of feed stock.

5. Shift Reaction
In the shift reaction CO is converted into CO2 by reaction with H2O
thereby generating H2 . Process gas from the reforming section enters
the medium temperature shift converter where conversion of CO into
CO2 takes place.

CO + H2O  CO2 + H2O

 6. Process Gas Cooling
The process gas leaving the shift converters is cooled down in the
existing series of heat exchangers. The inlet temperature to MT shift
converters has been changed to 210C in line with the present
catalyst. After cooling down of the process gas to 40 C the process
condensate is separated in the 2nd process condensate separator and
recycled to the deaerator.

The shifted process gas contains H2, CO2, a minor amount of CO and
a slip of methane. The H2 content is purified in the existing PSA unit
to meet the required product quality.

7. PSA
The PSA unit consists of a number of beds operating in cycles.
Impurities are selectively adsorbed on an adsorbent at a high pressure
thereby producing high purity(99.9%) H2 . By reducing the pressure
the impurities are desorbed and thereby adsorbent is regenerated.
Every adsorber operates on a repeated cycle basis consisting of
adsorption and regeneration phases (swing) without changes in the
temperature, except for those caused by the heat of adsorption and
desorption.

The H2 product from the PSAunit is directed directly to the battery

limit. A minor amount of hydrogen, after compression in the H
recycle compressor is recycled to the process feedin the
desulphurization section.
The PSA off-gas separated from the product hydrogen and containing
the other components in the PSA feed together with the remaining H
is sent to the reforming section as a primary fuel for the tubular
reformer.
 A PROJECT ON
EFFICIENCY OF PROCESS GAS BOILER
 BOILER

Hydrocarbon steam reforming is an endothermic process driven by

energy supplied to the reforming catalyst by the combustion of fuel
gas in the reformer box. The combustion heat is transferred from the
hot flue gas in the firebox to the catalyst and the process gas through
the walls of the catalyst tubes. The converted feedstock or process gas
leaves the fired section at temperatures typically between 800° and
950°C.
The process gas is then cooled in a process gas boiler to the
temperature required for entering the downstream water-gas shift
section that allows for additional hydrogen production by carbon
monoxide (CO) conversion. The heat of the process gas is transferred
to boiling water and recovered as valuable high-pressure steam, which
may be superheated and used partially as process steam with the
balance monetized as steam export.
The heat exchange surface is divided into two chambers separated by
an intermediate channel equipped with an external bypass system
controlling the heat duty of the second chamber. The independent
design of the two compartments allows for greater flexibility for the
selection of tube diameter and length, saving money.
The bypass valve provides accurate control of the outlet temperature
for clean and fouled conditions to obtain the desired temperature
upstream of the shift section. The design complies with the typical
operating window for the process gas boiler and achieves the target
outlet temperature for design parameters of plant turndown and
fouling factors by a thorough understanding of the internal flow
regimes.
CALCULATING THE EFFICIENCY OF PROCESS GAS BOILER
Process Gas Boiler uses heat of process stream from steam reformer
to generate steam.
Composition of process gas stream:
H2O: 28.78%
N2: 0.0728%
H2: 51.81%
CO: 11.64%
CO2: 4.86%
CH4 : 2.83%
Boiler Efficiency is defined as ratio of useful heat output to total
energy input.
Required Data of Process stream:
Boiler Inlet Boiler Outlet
Temp. 895oC 335oC
Pressure 25 bar 25 bar
Cp(Kcal/KgoC) 0.739 0.661

Total Mass flow rate: 60766 Kg/hr

Boiler generates saturated steam from saturated water at 43 bar
pressure.
Steam generation rate: 56 ton/hr
Latent heat of vaporisation of water at 43 bar: 1690.32 KJ/Kg
Calculations:
Heat input to the boiler: m*Cp,avg*(T2-T1)
m = 60766 Kg/hr
Cp,avg = (Cp1 + Cp2)/2
= (0.739 + 0.661)/2 = 0.7 Kcal/KgoC
T2 = 895oC
T1 = 335oC
Total heat input = 60766*0.7*(895-335)*4.18 = 99.5687*106 KJ/hr.

Total heat to Produce steam:

Q= M*Hv
Hv = 1690.32KJ/Kg
M = 56000 Kg/hr
Heat Q = 56000*1690.32 = 94.657*106 KJ/hr.

Boiler Efficiency = (Heat output/ Heat input)*100

= (94.657/99.5687)*100 = 95.06%

Efficiency of Process gas boiler used in HGU is 95.06%

 CONCLUSION

After the completion of industrial training, we enhanced competencies

& competitiveness in our respective area of specialization. We tried to
relate the experience in the workplace with knowledge learned in the
institute & applied on the job under supervision. Here, we gained the
experience and knowledge that can be used for suitable job without
delay after studies. We learned to hone soft skills appropriate to the
work environment. Also get improvised in communication skills. We
assessed career ability, knowledge & confidence as well as enhanced
our marketability to be more competitive. With experience,
knowledge & skills acquired during industrial training, we will be
better prepared to face working world.