Report

Bharat Oman Refineries Limited
Kunal Parwani Internship Report
A PROJECT REPORT ON FRACTIONATOR FEED FURNACE AND REACTOR

EFFLUENT/FEED HEAT EXCHANGER EFFICIENCY AND HEAT EXCHANGER
NETWORK DESIGN
PROJECT REPORT SUBMITTED IN FULFILMENT OF SUMMER INTERNSHIP

AT
BHARAT OMAN REFINERIES LIMITED

BINA, DIST. SAGAR (M.P.)
SUBMITTED TO:
SUBMITTED BY:
KUNAL PARWANI
B.TECH.
CHEMICAL ENGG(2ND YEAR)
IIT MADRAS.
CERTIFICATE
This is to certify that the training report entitled FRACTIONATOR FEED

FURNACE AND REACTOR EFFLUENT/FEED HEAT EXCHANGER
EFFICIENCY AND HEAT EXCHANGER NETWORK DESIGN submitted by
KUNAL PARWANI to INDIAN INSTITUTE OF TECHNOLOGY MADRAS for
the award of the degree of Bachelor Of Technology in Chemical
Engineering is a bonafide record of the internship carried out by him
under my supervision from 4th June 2012 to 18th July 2012.
Mr. SANJEEV VERMA
Mr.
Mr. A.P. RAGHAV
VICE PRESIDENT
PROCESS MANAGER
ASST. VICE PRESIDENT
BORL, BINA, M.P.
BORL, BINA, M.P.
BORL, BINA, M.P.
ACKNOWLEDGEMENT
I am thankful to Mr. Sanjay Singh, Senior Managar (HRD & ADMIN), BHARAT OMAN REFINERIES LMTD, BINA
for giving me an opportunity of 6 and a half week internship at the Integrated Hydrocracker/Diesel
Hydrotreater Unit(HCU/DHT).
I express my gratitude to Mr. Harshvardhan Tomar, Deputy Manager (HRD) for his extremely valuable
guidance and constant encouragement in my work.
I am cordially grateful to Mr. KSV Srinivas (Manager, HCU/DHT) for his valuable feedback throughout the
internship period.
I am extremely thankful to Mr. Vikas Kashyap and Mr. Abhai Shukla, for their patient guidance and provision
of data that was necessary for my project work.
I am also thankful to other staff including Shift In-charges Mr. J.S. Selvan, Mr. Dilip Parmar, Mr. Rishikesh
Khandekar and all the Assistant Engineers for their co-operation during my vocational training period in the
HCU/DHT Plant.
Thanking You,
Kunal Parwani
B.Tech(2nd Year)
Chemical Engineering
IIT Madras.
INDEX
Contents
REFINING................................................................................................................................................................ 5
INTRODUCTION TO BINA REFINERY .......................................................................................................................... 6
INTEGRATED FULL CONVERSION HYDROCRACKER AND DIESEL HYDROTREATER.........................................................14
PROCESS VARIABLES...............................................................................................................................................19
GENERAL CHEMISTRY IN HCU/DHT..........................................................................................................................26
PERFORMACE EVALUATION OF HCU FRACTIONATOR FEED FURNACE........................................................................33
FURNACE EFFICIENCY .............................................................................................................................................35
INDIRECT METHOD FOR CALCULATION OF EFFICIENCY .........................................................................................36
APPROXIMATE METHOD FOR CALCULATING HEATER EFFICIENCY: .........................................................................38
RESULTS.............................................................................................................................................................38
VARIOUS TRENDS IN FURNACE EFFICIENCY ..........................................................................................................39
EFFECT OF GROSS CALORIFIC VALUE OF FUEL ON EFFICIENCY............................................................................39
EFFECT OF PREHEATED AIR TEMPERATURE ON EFFICIENCY ...............................................................................40
EFFECT OF FLUE GAS TEMPERATURE ON EFFICIENCY ........................................................................................41
OBTAINING DATA ...............................................................................................................................................41
MODELLING AND SIMULATION OF HEAT EXCHANGER NETWORK..............................................................................42
PRINCIPLES OF PINCH ANALYSIS ..........................................................................................................................43
CASES CONSIDERED............................................................................................................................................44
ORIGINAL CASE...............................................................................................................................................44
ALTERNATIVE DESIGN CASE 1 ..........................................................................................................................45
ALTERNATIVE DESIGN CASE 2 ..........................................................................................................................46
RESULTS.............................................................................................................................................................47
OBTAINING DATA ...............................................................................................................................................47
PERFORMANCE EVALUATION OF 1st STAGE REACTOR EFFLUENT/DHT FEED HEAT EXCHANGER ..................................48
HEAT EXCHANGER ..............................................................................................................................................49
CLASSIFICATION OF HEAT EXCHANGER ................................................................................................................49
CALCULATIONS...................................................................................................................................................50
VARIOUS TRENDS IN HEAT EXCHANGER EFFICIENCY .............................................................................................51
VARIATION OF HEAT EXCHANGER EFFICIENCY WITH AREA OF HEAT EXCHANGE .................................................51
VARIATION OF HEAT EXCHANGER EFFICIENCY WITH OUTLET TEMPERATURE OF HOT STREAM ............................53
VARIATION OF HEAT EXCHANGER EFFICIENCY WITH MASS FLOW RATE OF HOT STREAM ....................................53
OBTAINING DATA ...............................................................................................................................................54
REFINING
The process of separating crude oil into the useful products with desired set of properties and purities is
called refining. In general, refinery perform three different functions:
Separate crude oil into different streams such as LPG, Naphtha, Kerosene, Diesel components etc by
fractional distillation .
Chemically convert some of the lower valued fractions into more desirable products in Secondary units;
and
Treat intermediate products by removing unwanted elements and compounds for blending into final
end products.
Various hydrocarbon fractions which are separated by distillation and upgraded in secondary units are
blended to make desired products like petrol, diesel.
Unlike chemical manufacturing, petroleum products almost never have a specific chemical composition,
but rather are complex mixture of thousands of compounds, which are never separated are identified
individually. Instead , the mixtures are characterize by properties such as boiling ranges, freezing points,
sulphur content etc.
Each step in the refining process is designed to add value to its inputs.
Crude Oil
Crude Oil a naturally occurring complex hydrocarbon mixture of thousands of different hydrocarbon
molecules (Paraffins / Naphthenes /Aromatics) with carbon atom chain commencing from C1 to
C40+with following composition.
Carbon
83 to 87%
Hydrogen
11 to 15%
Sulphur
0.1 to 6 %
Crude oil molecules have different boiling temperatures and molecular weights.
INTRODUCTION TO BINA REFINERY

Bharat Oman Refineries Limited (BORL) is a Project promoted by Bharat Petroleum Corporation Ltd (A Govt.
of India Undertaking) & Oman Oil Company Ltd. (wholly owned by Govt. of Sultanate of Oman).
It has set up of 6 MMTPA Refinery complexes at Bina in the district Sagar in the state of Madhya Pradesh for
production of petroleum products. The refinery is designed for Arab Mix Crude (65% heavy, 35% light) and
other Middle East crudes. The Project Management Consultant (PMC) for the entire project is M/s. Engineers
India Limited (EIL).
The project has followings facilities.

6 MMTPA refinery located at Bina, District Sagar, (M.P) for production of petroleum products.
Crude receipt & dispatch facilities comprising a Single Point Mooring (SPM) system and a Crude Oil
Terminal (COT) at Vadinar, District Jamnagar (Gujrat), and a 935 km cross country crude oil pipeline
(24 diameter) from Vadinar to Bina pipeline (VBPL).
Pet Coke based Captive Power Plant (CPP) of 99 MW (33 x 3),
Infrastructure facilities at the refinery as well as at COT e.g., township water supply system, etc.
1) REFINING PROCESSES:
Crude Oil comprises complex chains of hydrocarbons having Carbon and Hy drogen molecules and it also
contains impurities like compounds of Sulphur, Nitrogen and oxygen, metals, etc.
2) REFINERY CONFIGURATION:
Bina Refinery is designed to process 6 MMTPA of Arab Mix crude (65% Arab Light and 35% Arab Heavy) but it
will also have the flexibility to process other types of Middle East crudes, adopting the state of art
technologies with configuration of following units:
1.
2.
Primary Processing facilities:
Crude Distillation Unit(CDU)
Vacuum Distillation Unit(VDU)
Secondary Processing Facilities:
3.
Motor Spirit Block(MSB)
Hydrocracker Unit(HCU)
Delayed Coker Unit(DCU)
Treating Units:
LPG Treating unit
ATF Merox
Diesel Hydrotreater
4.
Sulphur Recovery Block(SRB)
5.
Hydrogen Generation Unit(HGU)
6.
Captive Power Plant(CPP)
7.
Utilities systems:
Raw Water intake system
Raw water treatment plant
Cooling Tower and Cooling water treatment plant
Reverse Osmosis based Demineralization (RODM)
Nitrogen plant and Effluent Water Treatment Plant(ETP)
CRUDE
GAS
LPG
NAPHTHA
SKO
CDU
MOGAS
BLOCK
RC
O
VDU
HSD EIII
HSD EIV
:
MS EIII
MS EIV
LVGO
HVGO
HYDROCRACKER/
DIESEL
HYDROTREATER
C HGO &
C Naphtha
VR
DELAYED
COKER
POWER
PLANT
H2
LCGO
SOUR
GAS
HYDROGEN
SOUR
WATER
SULPHUR
BLOCK
SULFUR
The major products of Bina Refinery are:
Fuel Gas
Liquefied Petroleum Gas(LPG)
Naphtha
Euro III Motor Spirit (MS)
Euro IV Motor Spirit (MS)
SKO
Aviation Turbine Fuel(ATF)
Euro III HSD
Euro IV HSD
Sulphur
Pet Coke
CAPACITY OF UNITS
Units
Crude / Vacuum Distillation Unit
Full Conversion Hydrocracker (HCU)
Diesel Hydrotreater
Delayed Coker Unit
Hydrogen Unit
Naphtha Hydrotreater
CCR Reformer Unit
Isomerization Unit
Sulphur Recovery Unit
Capacity (MMTPA)
6.0
1.95
1.63
1.36
0.07
1.0
0.5
0.3
2 x 180 MTPD
DESCRIPTION OF UNITS
Crude & Vacuum Distillation Unit (CDU/VDU)
The purpose of this unit is to fractionate crude oil into specific boiling range streams suitable for blending
into final refined products or as feedstock to downstream processing units. Products produced from this unit
are Gas, LPG, Naphtha, Kerosene / ATF, Light Gas oil (LGO) and Heavy Gas oil (HGO). Remaining residue as
Reduced Crude Oil (RCO) from CDU is a feed to Vacuum Distillation Unit (VDU) for further distillation under
vacuum conditions. Products from VDU are Vacuum Diesel which forms a part of Diesel product whereas
Vacuum Gas Oil (VGO) consists of Light Vacuum Gas oil (LVGO) & Heavy Vacuum Gas oil (HVGO) forms a feed
to Full Conversion Hydrocracker (FCHC). Vacuum residue (VR) is a feed to Delayed Coker Unit (DCU).
Waste heat from the LGO & HGO process stream is recovered in a steam generation system. The system
consist of two nos. of MP steam (18.0 Kg/cm2g pressure) generators with a common steam drum & two nos.
of LP steam (5.5 Kg/cm2g pressure) generators with a common steam drum along with associated facility e.g.
BFW treatment facility etc.. CDU/VDU is designed by M/s Engineers India Ltd.
Integrated Full Conversion Hydrocracker (FCHC) & Diesel Hydrotreater (DHT)

The primary objective of the FCHC is to maximize diesel production with sulphur content less than 10 ppm
and Cetane Index more than 51. The DHT desulphurises the high sulphur diesel produced from the CDU/VDU
& DCU and also improves the cetane no. of these streams to meet Euro III / IV quality norms.
BORL has two stages Hydrocracker integrated with Diesel Hydrotreater for saving capital cost and this kind of
integrated unit is first of its kind in India. Process involves Hydro cracking of VGO and Heavy Coker Gas Oil
(HCGO) at high pressure and temperature in presence of suitable catalyst and Hydrogen. Technology licensor
for this stateofart unit is M/s Chevron, which is a reputed licensor in this field.
Waste heat from I stage reactor effluent, HGO pump around & convection section of I stage & II stage
reactor feed heater is recovered in a steam generation system. The system consist of three nos. of MP steam
(18.0 Kg/cm2g pressure) generators with a common steam drum along with associated facility e.g. BFW
treatment facility etc.
Delayed Coker Unit (DCU)

Delayed Coker process is based on severe thermal cracking of VR to produce distillate products and
petroleum coke. Feed to DCU is heated and fed to Coke drums, the hot feed cracks to form coke and vapours,
vapours leave the coke drum which is fractionated to get cracked products like Gas, LPG, Naphtha, Lt. Coker
Gas Oil (LCGO) and HCGO. These offspec products are further processed in secondary processing unit like
FCHC & DHT for making on spec product. Coke from the field coke drum is removed by hydraulic decoking
method.
Waste heat from HCGO product stream & pump around stream is recovered in a BFW pre heater & two MP
steam (18.0 Kg/cm2g pressure) generator This technology is provided by M/s ABBLummus. Coke will be
utilized for steam and power generation in Captive Power Plant which is CFBC (Circulating Fluidized Bed
Combustion) type Boiler based power plant.
Naphtha Hydrotreating Unit / Naphtha Splitter Unit (NHT / NSU)

Naphtha Hydrotreating Unit (NHT) process involves catalytic treatment of naphtha to remove sulphur and
other impurities from naphtha. NSU (Naphtha Splitter Unit) is required for splitting full range naphtha to Lt.
& Hy. Naphtha. The light naphtha is feed to PENEX unit and Hydrogen unit and whereas heavy naphtha is a
feed to CCR (Continuous Catalyst Regeneration) unit. NHT process is Licensed by M/s UOP.
Continuous Catalyst Regeneration & Reforming Unit (CCR)
This unit produces high octane MS component from Hy naphtha to finally produce high quality unleaded
petrol. Hydro treated heavy naphtha from NHT is combined with recycle gas and sent to a series of reactors.
Reactor effluent is separated into Gas, LPG and Reformate streams. Continuous circulation of regenerated
catalyst helps maintain optimum catalyst performance at high severity conditions for long on-stream periods
of reforming operations.CCR Process is licensed by M/s UOP.
Naphtha Isomerization Unit (PENEX)
Hydro treated light naphtha from NHT unit along with make up gas from CCR unit is fed into PENEX after pre
treatment. This unit isomerises normal C5 and C6 paraffin to their respective isomer, which have got higheroctane value with no Aromatics, Benzene and Olefins. The isomerate product when blended with reformate
produces MS meeting Euro III/IV specifications.PENEX Process is licensed by M/s UOP.
Hydrogen Generation Unit (HGU)
Hydrogen Generation Unit Licensed by M/s Technip Benelux B.V produces Hydrogen by steam reforming of
naphtha. Hydrogen purity of 99.9 percent is achieved through the UOP Pressure Swing Adsorption (PSA)
Unit.
LPG Treating Unit(LPGTU)

The primary purpose of the LPG treating units is to remove mercaptans so that final product meets sulphur
and corrosion specifications. Sulphur present in LPG in the form of mercaptans is removed by catalytic
oxidation of mercaptans. The process is used for LPG sweetening.
Unit is designed by M/s Engineers India Ltd.
ATF Merox Unit
The objective of this unit is to convert Mercaptans & Sulphur compounds present as impurities in ATF to
disulphide oils. The process converts the mercaptans to disulphide oils by their oxidation in presence of
suitable catalyst.
Sulphur Recovery Unit (SRU) and Tail Gas Treating Unit (TGTU)
The main objective of Sulphur Recover Unit (SRU) is to remove and recover the Sulphur from Hydrogen
Sulphide (H2S) rich gas stream which is formed in various secondary processing units like HCU/DHT/NHT.
H2S rich gas is the feed to SRU. It is having two parallel trains. Each train is having Main combustion chamber
to convert H2S (1/3rd) into SO2 & two stage Clause reactor to convert H2S (96%) into S. SRU technology is
based on Claus process. Sulphur compounds are further treated in Tail Gas Treating Unit (TGTU) in presence
of suitable catalyst and are converted to H2S which is fed back to SRU for Sulphur recovery & un recovered
H2S is burnt in incinerator. Over all Sulphur recovery can be achieved by both the unit in combination is 99.9
(min.)%. Waste heat from main combustion chamber effluent gases, I stage reactor effluent gases &
incinerator effluent is recovered in a steam generation system. The system consist of three nos. of MP steam
(18.0 Kg/cm2g pressure) generators with separate steam drum & four nos. of LP steam (5.5 Kg/cm2g
pressure) generators along with associated facility e.g. BFW generation & BFW treatment facility etc.. SRU is
licensed by M/s Engineers India Ltd and TGTU is licensed by M/s SIIRTEC NIGI (SINI)
Captive Power Plant (CPP)
As a part of utilities, Captive Power Plant (CPP) is being established. CPP shall be of 3 X 33 MW capacities & 3
x 275 Tons/Hr steam generating facilities. The CPP shall be Circulating Fluidized Bed Combustion ( CFBC )
type Boiler based Power plant, generating power through Steam Turbine Generators using Petroleum Coke
as main fuel. Petroleum coke shall be produced in one of the refinery process units i.e. Delayed Coker Unit.
Lime stone shall be added to capture sulphur & control Sox emissions from the flue gases. The package is
being executed through LSTK contract by Bharat Heavy Electricals Limited (BHEL).
A. PRODUCTS
The product slate favours maximization of Middle Distillate (ATF & HSD) and minimization of Furnace Oil.
Bina Refinery configuration is capable to produce Euro-3/Euro-4 quality specifications of Gasoline & Diesel
Products. Sulphur is the by product from the refinery.
Products
LPG
Naphtha
Euro III MS
Euro IV MS
SKO
ATF
TMTPA
234
272
385
400
441
500
% of Total
3.90%
4.53%
6.42%
6.67%
7.35%
8.33%
Products
Euro III HSD
Euro IV HSD
Sulphur
Surplus Coke
Fuel & Loss*
Total Crude Refining
TMTPA
1871
1000
109
103
685
6000
% of Total
31.18%
16.67%
1.82%
1.72%
11.41%
100.00%
INTEGRATED FULL CONVERSION HYDROCRACKER AND DIESEL HYDROTREATER

Overall Process Loop
SR Diesel/LCGO Feed
Make-Up H2
VGO/HCGO/LCN Feed
Section
PSA H2
HCR Reaction
Quench
Injection Water
Lean Amine
HLPS and 1 st
Stage & DHT
HHPS
Vapour
Recycle Gas
Section
CLPS
Liquid
Heat From
Reactor Effluent
2 nd Stage HHPS
Vapour (H2)
Section
DHT Reaction
Rich Amine
Sour Water
Section
HLPS Liquid
Treated CLPS
Vapour
UCO Bleed
HLPS Liquid
HCR
HCR Diesel
Fractionation
Kerosene/ATF
UCO
HCR Light Diesel
Fresh Caustic
Sour Offgas
DHT
Fractionation
LER & LPG

Unstabilized
Naphtha and
Sour Gas
Treated LPG
Stabilized Light Naphtha
Treating
Heavy Naphtha
Spent Caustic
Sour Water
DHT Diesel
DHT Kerosene
As shown by the block flow diagram, the process consists of seven sections:
HCR Reaction Section

DHT Reaction Section
Recycle Gas Section
HCR Fractionation Section

DHT Fractionation Section
Light Ends Recovery and LPG Treating Section
Make-Up Hydrogen Compression Section
The reaction sections contain a two-stage HCR and a DHT in a single high pressure loop. The HCR reaction section
converts fresh VGO and HCGO into mid-distillate and lighter products as well as hydrotreat a light coker naphtha
stream. In the first-stage HCR reactor, the feed is hydrotreated and partially converted. Nitrogen levels must be
low in the first-stage product in order to obtain high second-stage activity and prevent premature deactivation of
the second-stage catalyst. The integrated DHT reaction section uses the hydrogen-rich hot high pressure
separator (HHPS) vapour from the second HCR stage and heat from the first-stage reactor effluent to hydrotreat
fresh straight-run diesel and LCGO.
The recycle gas section contains equipment to separate and clean the hydrogen-rich gas from the reactor effluent
for reuse in the reaction section. Initially a series of pressure separators splits the reactor effluents into vapour
and liquid streams. Water injected upstream of the reactor effluent air cooler removes nearly all of the NH 3 and
some of the H2S from the process in the form of ammonium bisulfide. The vapour streams are treated with lean
amine to remove all but a trace of remaining H2 S. The treated gas is then compressed to be used as reactor
quench or feed gas.
The purpose of the HCR and DHT fractionation sections is to separate reactor effluents into the desired naphtha,
kerosene, and diesel products. HCR fractionator bottoms containing unconverted first-stage and second-stage oil
serve as feed for the second-stage HCR reactors. Though not required by design, provisions have been provided
to bleed off unconverted oil (UCO) for polycyclic aromatic conce ntration control. The sour gas and naphtha
streams from both the HCR and DHT fractionation sections are sent the light ends recovery and LPG treating for
additional processing.
The LER and LPG treating section is designed to take the sour gas and naphtha from the HCR and DHT
fractionation sections and produce sour fuel gas, treated LPG, light naphtha, and heavy naphtha. This section
contains a deethanizer, debutanizer, sponge oil absorber, and naphtha splitter. The sour fuel gas and water are
first removed at the deethanizer overhead drum. To increase LPG recovery, vapour from the deethanizer
overhead drum is contacted with heavy naphtha from the naphtha splitter in a sponge oil contactor. Deethanizer
bottoms product is then separated into sour LPG and full range stabilized naphtha at the debutanizer. A caustic
wash section treats the LPG. Full range naphtha from the debutanizer, HCR fractionator, and DHT fractionator are
combined and then separated into light and heavy naphtha at the naphtha splitter.
The make-up hydrogen compression section consists of three identical parallel compressor trains, each with three
stages of compression. During normal operation two trains are in use and compress fresh make-up hydrogen to
reaction section pressure. The compressed make-up hydrogen is combined with hydrogen recycle gas to form
HCR first- and second-stage reactor feed gas.
Integration of HCU/DHT
Integrated through hydrogen, heat, and light ends recovery.
Feed gas for the DHT reactor is supplied by the vapour overhead off the second-stage hot high pressure separator
(HHPS).
The HCR reactor effluent/DHT reactor feed heat exchanger serves as the DHT reactor furnace.
The sour gas, liquefied petroleum gas, and naphtha from the HCR and DHT fractionation sections are separated at
one light ends recovery section.
The reaction section consists of a two-stage full conversion hydrocracker using ISOCRACKING technology integrated
with a DHT in a single high pressure loop. There are three first-stage reactors with an inter-reactor exchanger located
between the second and third first-stage reactors. There are two second-stage reactors and a single DHT reactor.
First-stage reactor effluent provides heat for the DHT reactor feed and the second-stage hot high pressure separator
(HHPS) provides a clean, hydrogen-rich stream for the DHT inlet gas. The two-stage HCR maximizes the production of
<10 ppmw sulphur mid-distillate products. The DHT produces <50 ppmw sulphur mid-distillate product with a
reasonable cetane improvement. The secondary products are liquefied petroleum gas (LPG), light and hea vy naphtha,
and kerosene/ATF.
The recycle gas section contains equipment to separate and clean the hydrogen-rich gas from the reactor effluent for
reuse in the reaction section. Initially a series of pressure separators splits the reactor effluents into vapour and liquid
streams. Water injected upstream of the reactor effluent air cooler (REAC) removes nearly all of the NH3 and some of
the H2S from the process in the form of ammonium bisulfide. The vapour streams are treated with lean amine to
remove all but a trace of remaining H2S. The treated gas is then compressed to be used as reactor quench or feed gas.
Gas released from the liquid let down from the high pressure section is separated, treated with lean amine to remove
all but a trace of H2S, and water washed to remove any NH3 before going offplot for hydrogen recovery.
The product stripper, fractionator, and three sidecut strippers in the HCR fractionation section are designed to
separate the liquid into the desired products, meeting the required product specifications. The purpose of the product
stripper is to remove H2S and stabilize the low pressure separator liquid. The product stripper consists of six valve
trays in the rectifying section and two random packed beds in the stripping section.
The DHT fractionation section is designed to separate the liquid products from the DHT reaction section and prod uce
diesel as the primary product. Naphtha and kerosene are separated from the diesel product, and the naphtha is
routed to the light ends recovery section for further processing while the kerosene is combined with kerosene in the
HCR fractionation section and sent offplot. The product stripper overhead, a mixture of light naphtha, LPG, and light
gases is cooled in the DHT product stripper overhead air cooler before flowing to the DHT product stripper reflux drum.
The reflux drum gases and part of the condensed liquid are sent to deethanizer overhead condenser in the light ends
recovery section. The remainder of the liquid returns to the product stripper as reflux via the DHT product stripper
reflux pumps. The sour water from the reflux drum is sent to the sour water break drum.
The light ends recovery section was designed to take the sour gas and unstabilized naphtha from the fractionation
section and produce LPG, light naphtha, heavy naphtha, and sour offgas as products.
The feed to the light ends recovery section is comprised of the naphtha and offgas from the product stripper reflux
drum in the HCR fractionation section and DHT product stripper reflux drum in the DHT fractionation section. Along
with the sponge oil absorber bottoms, the combined stream is sent through the deethanizer overhead cooler to the
deethanizer reflux drum. The sour water from the deethanizer reflux drum is sent to the sour water break drum.
The debutanizer stabilizes the naphtha and separates LPG as the overhead liquid prod uct. It consists of 24 valve trays
in the stripping section and 18 valve trays in the rectifying section. This column also has a thermosiphon that
exchanges heat with the heavy diesel pumparound from the fractionator.
The debutanizer bottoms product is combined with naphtha from the HCR and DHT fractionator overhead systems
and flows to the naphtha splitter. The splitter separates the naphtha into light naphtha (C 5 to 90C) and heavy
naphtha (90-145C).
The LPG treating system removes H2S and free water to meet sales specifications. LPG from the debutanizer is
combined with a caustic recirculation stream and make-up caustic stream. The LPG and caustic stream flows through
a static mixer and mixing valve to ensure good contacting between the hydrocarbon and caustic solution. The phases
are then separated in the caustic washer. The design is based on 20 wt % caustic make -up.
This section presents the process requirements for the make -up hydrogen compression section. The purpose of the
compression section is to compress the make-up hydrogen from a supply pressure of 20.0 kg/cm 2 (g) to the reactor
section pressure of about 185.0 kg/cm 2 (g). The make-up hydrogen compression facility consists of three identical
parallel trains, each with three stages of compression. The first-stage suction drum (16-VV-VI-801) is common to all
trains as any two of the three trains will run together during normal operation to supply 100% of the make -up
hydrogen requirement, with the remaining 10% spilling back to the first-stage suction drum.
PROCESS VARIABLES
This section describes the effects of changing key process variables on the operation of the BORL hydrocracking (HCR)
unit employing ISOCRACKING technology and the diesel hydrotreating (DHT) unit. Specifically, the variables discussed
in this section are listed below:
Feed Effects
Hydrogen Effects
Catalyst Effects
Reaction Sections Operation Effects
Fractionation and Light Ends Sections Operating Effects
On each catalyst pellet there are millions of what are called active sites. On these active sites, the feed is converted
to products. As the catalyst temperature is increased, the active sites work faster and upgrade more feed to products.
As some active sites become inactive (through catalyst fouling or poisoning) a higher catalyst temperature is required
to obtain the same conversion of feed to products from the remaining active sites.
Thus, if the HCR operation is to be changed, there are two things to consider with respect to the catalyst. What
catalyst average temperature (CAT) is required to achieve the desired conversion and how does the change in CAT
affect the catalyst fouling rate (C/month the CAT must increase to maintain the desired product specification).
Figures at the end of this section illustrate the effect of process variables on CAT requirements. The catalyst life can be
estimated from the actual CAT, the expected fouling rate, the normalized CAT and the predicted end -of-run (EOR) CAT.
Feed Boiling Range and Viscosity

The HCR feed is a mixture of many different sized molecules. The composition and quality of the feed mixture is
dependent on the crude oil used and the operating conditions of the upstream units. The primary funct ions of the
HCR unit are remove sulphur and nitrogen and crack the large gas oil molecules to smaller naphtha, kerosene, and
diesel.
As the feed boiling range increases, the levels of nitrogen, polycyclic aromatics (PCA), asphaltenes, and metals also
increase. A higher feed nitrogen and PCA level require an increased CAT to maintain conversion. In addition,
increased PCA, asphaltene, and metal levels also increase the catalyst fouling rate. Therefore, increasing the feed
boiling range shortens the expected run span (catalyst life) by increasing both the required CAT and the fouling rate.
Feed Nitrogen
HCR feed nitrogen is a temporary catalyst poison. Nitrogen tends to exist as basic compounds in the feed. The sites
on the catalyst that crack the feed are acidic. The nitrogen is adsorbed on the acidic active sites, thus neutralizing their
effectiveness to crack the feed. The remaining unaffected active sites must crack more feed to compensate for the
neutralized sites. Thus, with a higher level of feed nitrogen, a higher CAT is required to achieve a desired conversion.
If the feed nitrogen is lowered, some of the nitrogen neutralizing the active sites will desorb; however, nitrogen
desorption is very slow in comparison to nitrogen adsorption. Thus, if the feed nitrogen is lowered, the new
equilibrium amount of nitrogen adsorbed on the active sites may not be reached for several days. In some extreme
cases where the feed nitrogen is drastically reduced, the new equilibrium may not be reached for sev eral weeks.
In the DHT reactor, nitrogen compounds in the feed are converted to NH 3. The NH3 is subject to do one of three
things: (1) the NH3 will be absorbed into the water phase in the separator, (2) the NH 3 will react with H2S and form
NH4SH which is then pulled out with the wastewater, or (3) NH 3 can react with Cl that comes in with the feed to form
NH4Cl which can potentially precipitate out and foul effluent heat exchangers if not monitored. This NH 4Cl is also very
corrosive if a solution is allowed to form and remain stagnant. Reducing the nitrogen concentration of the
hydrotreater feed results in less catalyst fouling and less byproduct.
Feed Asphaltenes and Metals

Feed asphaltenes and heavy metals must be limited to very low levels to prevent rapid catalyst deactivation. The
contribution of each to catalyst deactivation is discussed below.
Asphaltenes are hydrogen-deficient, condensed-ring molecules which boil well over 550C. Because of their structure
and large size, they are difficult to crack and saturate and may polymerize on the catalyst surface as carbonaceous
deposits. With proper operation of upstream units, asphaltene content of the HCR feed should not exceed 100 ppm.
Even short-term poor operation of upstream units can result in high asphaltene levels in the HCR feed (over 100 ppm)
and cause significant catalyst coking and fouling.
Heavy metals, particularly nickel and vanadium, in addition to alkalis (such as sodium) and alkaline earths (such as
calcium and magnesium) are deposited on the catalyst and irreversibly destroy its activity. These metals are found
predominately in asphaltenes; however, they are sometimes present in other molecular forms such as porphyrins .
Porphyrins are large condensed ring-like molecules that boil at a lower temperature than asphaltenes. In addition,
silicon in the feed can greatly poison the catalyst. Operation at higher levels of silicon will severely affect the life of the
catalyst.
Metal concentrations as low as 1 ppm in the feed can have a significant effect on catalyst fouling. Although the
catalyst pellets look solid, each is full of tiny pores that oil and hydrogen molecules can enter and then react on an acid
site. For the HCR/DHT units reaction to take place oil and hydrogen molecules must either diffuse into the catalyst
pores to reach an acid site or contact an acid site on the surface of the catalyst. Metals, however, are too large to fit
inside the catalyst pores so they react on the outside of the pellet. Thus, when metals are deposited on the catalyst
surface, they not only foul the active sites on the outside of the catalyst, but also block feed from reaching the active
sites inside the pores. Consequently, even small amounts of feed metals can foul the catalyst very quickly.
Iron carried in with the feed can be a troublesome contaminant. It may be chemically combined with the heavy
hydrocarbon molecules, or it may exist as a suspended particulate matter. In either case, it not only deactivates the
catalyst through port plugging but also plugs the catalyst interstices such that excessive pressure drop may develop.
Normally this plugging would appear as a crust at the top of the first reactor bed. The feed filters are intended to
reduce the amount of iron particulates reaching the catalyst beds and mitigate plugging. The top bed of the first -stage
HCR and hydrotreating reactors contain layers of grading/catalyst to further minimize any potential plugging as well as
remove other potentially harmful metals and silica.
Polycyclic Aromatics
PCAs are catalyst coke precursors. These large multi-ring aromatic compounds tend to dehydrogenate on the catalyst,
ultimately forming coke. Consequently, the amount of these compounds in the feed has a significant effect on catalyst
activity and fouling rate.
Feed Sulphur
For the HCR/DHT units, the metallurgy and corrosion allowances were based on a specific feed sulphur content.
Extended operation on combined feeds with higher than design feed sulphur content would shorten the useful life of
the reactor and other equipment in the plant.
Running high sulphur feeds may increase the H2S content of the recycle gas, decrease hydrogen partial pressure, and
reduce overall catalyst performance.
Feed Chlorides
In HCR and DHT units, salt (inorganic water-soluble compounds such as NaCl, MgCl, etc.) content of the feed
determines how rapidly salt builds up at the top of the first-stage reactor. If a salt crust builds up, reactor pressure
drop will increase, and can rise to the point where pressure drop may limit the feed rate to the unit and require a
shutdown. In addition to causing catalyst plugging, excessive organic and inorganic chlorides may cause fouling and
stress corrosion cracking in the feed/effluent heat exchangers. Chlorides can also combine with ammonia produced in
the reactors to form ammonium chloride which may plug and corrode reactor effluent exchangers and coolers as
mentioned in the feed nitrogen section of this manual. Desalted oil feeds may still contain trace amounts of organic
and inorganic chlorides and should be analysed frequently to ensure that the chloride level in the feed is kept to a
minimum.
Oxygenated Compounds
In HCR/DHT units there is evidence that oxygenated compounds cause reactor bed plugging, furnace tube fouling, and
heat exchanger fouling. Care should be taken in the operation of feed tankage and blanketing of the feed surge drum
to exclude oxygen from the feed.
Hydrogen Partial Pressure

An increase in hydrogen partial pressure suppresses the coke fouling of the catalyst and maintains low nitrog en levels
in the products. Thus, the hydrogen partial pressure should be maximized within the mechanical limits of the reactor
system to maximize run length.
An increased hydrogen partial pressure in HCR reactors causes more aromatic molecules to be con verted to
naphthenic molecules. This improves the smoke point and cetane number for mid-distillate products.
An increased hydrogen partial pressure in DHT reactors will yield similar cat life improvements to those realized in the
HCR. Increased partial pressure of the DHT will also aid in saturation of more difficult molecules and the removal of
more deeply bedded sulphur and nitrogen components.
The hydrogen partial pressure can be maintained or increased by:
Increasing Total System Pressure

Increasing Bleed Gas Rate
Increasing Make-Up Hydrogen Purity
Increasing Recycle Gas Purity
Increasing Total System Pressure
Decreasing CHPS Temperature
Make-Up Hydrogen Rate

Most of the hydrogen fed to the HCR and DHT units is consumed chemically. A small amount is physically dissolved in
the products from the reactors and later flashes out in the CLPS, in the stripping section, and in the offplot gas
recovery facilities.
A higher gas rate helps to evenly distribute the oil flow across the reactor by maintaining a higher pressure drop.
Good distribution is necessary to effectively use all the catalyst in the reactor and to minimize any potential hot spots
that would be caused by stagnant oil. Higher gas rates also improve heat transfer and flow regime uniformit y in the
furnace and heat exchangers.
Make-up hydrogen is fed to the reaction section as required on pressure control of the high pressure loop. Maximizing
total system pressure by operating as close as practical to the relief valve set pressure [HCR/DHT recycle compressor
knockout (KO) drum] will help maximize hydrogen partial pressure.
Make-Up Hydrogen Purity

Make-up hydrogen from the PSA unit consists of a mixture of hydrogen and methane. The methane concentration
builds to an equilibrium concentration in the recycle gas such that the amount in any bleed or leakage plus any
dissolved in the cold high pressure separator (CHPS) hydrocarbon equals the amount coming in with the make -up
hydrogen plus any methane formed in the reactors.
Since methane does not dissolve as readily as other light hydrocarbons in heavier hydrocarbon streams, the
concentration of methane in the recycle gas will be large relative to its concentration in the make -up gas. The result is
reduced hydrogen partial pressure in the reactors. Thus, to maintain the desired hydrogen partial pressure and
minimize the amount of impurities, especially methane, fed to the system, the purity of the make -up hydrogen should
be kept at the design value. If the make-up hydrogen purity falls below the design value, a bleed may be required to
maintain an acceptable hydrogen partial pressure.
Recycle Gas Rate
Recycle gas has four major functions listed below:

1. Maintaining high hydrogen partial pressure in the reactors. Without the excess hydrogen in the recycle gas, the
hydrogen concentration (partial pressure) would be very low in each reactor because most of the make -up
hydrogen is consumed by the reactions.
2. Providing a heat sink for the high heat of reaction in the catalyst beds. The reaction of hydrogen with the feed is
highly exothermic, several times the design heat duty of each of the reactor feed furnaces. The overall
temperature rise from this heat release is held in control by using quench gas; however, the quench gas can only
be added between reactors and between catalyst beds. Keeping a high gas rate (make -up gas plus recycle gas) in
the reactor limits temperature rise in a catalyst bed (30C maximum across any single bed) by spreading the
effects of heat release over a larger mass flow.
3. Distributing reactants over the catalyst. The two-phase reaction mixture of hydrogen-rich gas and oil is difficult
to distribute evenly across the catalyst in the reactor. A high recycle gas rate helps to evenly distribute flow
across the reactor by keeping the pressure drop through the beds in an optimum range. Good distribution is
essential to avoid hot spots in the catalyst caused by low flow or stagnant conditions which fail to effectively carry
away the heat of reaction.
4. Minimizing recracking of products by carrying them out of the reactor before they can recrack. The HCR
reactions take place in the oil-soaked pores of the catalyst. The cracked products are carried away from the
reaction sites in two ways:
By vaporising into the gas stream.

By trickling over the catalyst with the liquid which eventually leaves the reactor.
Any cracked product which remains in the liquid is likely to recrack, degrading to a less valued product. A high recycle
gas rate helps to vaporise products and carry them out of the reactor before they can overcrack.
All four effects of recycle gas discussed above are favoured by high recycle gas rates. These effects all help minimize
catalyst fouling.
Recycle Gas Purity

The hydrogen purity or hydrogen concentration of the recycle gas has a direct influence on the reactor hydrogen
partial pressure. High recycle gas purity yields high hydrogen partial pressures and minimizes catalyst fouling. The
recycle gas purity depends mainly on the make-up hydrogen purity and the yield of methane in the reactors. However,
the recycle gas bleed, CHPS temperature, and hydrogen consumption rate also have an effect. Taking a bleed, which
results in an increase in the make-up hydrogen rates, lowers the methane content of the recycle gas and improves
hydrogen partial pressure. Lowering the CHPS temperature will improve recycle gas purity because more light
hydrocarbons will condense out of the CHPS vapour, and because less hydrogen dissolves in the hydrocarbon at lower
temperatures, increased hydrogen concentration will be realized. The hydrogen consumption is dependent on
catalyst temperature, feed properties, and target conversion and cannot be controlled independently.
Catalyst Type
The type of catalyst used affects the performance and product yield structure of the unit. The catalysts loaded in the
HCR unit have the following purposes:
First-Stage HCR
ICR 122ZSB is a roughly 4 to 5 mm spherical catalyst. It provides size grading for removal of any particulates that
have not been removed by the feed filter. It also removes organically bound metals (usually nickel and vanadium)
from the feed so as to protect the more active catalyst downstream. It has essentially no activity for the removal
of sulphur or nitrogen, nor does it do any hydrocracking.
ICR 308QF is an active hydrodemetalation (HDM) catalyst that preserves the activity of downstream catalyst,
especially against silicon poisoning. ICR 308 is ideally suited for coker feedstocks. This layer of catalyst i s common
referred to as the silicon guard bed.
ICR 132NAQ is an active HDM catalyst that provides excellent HDM activity combined with high metals tolerance.
This catalyst is used to remove metal contaminants, such as Ni and V, from the feed. ICR 132 protects the
downstream hydrodesulphurisation (HDS) and HCR catalysts from fouling due to metals poisoning.
ICR 154LF is a high activity hydrotreating catalyst that performs deep HDS and hydrodenitrification (HDN). It
converts sulphur and nitrogen in the feed into H2S and NH3.
ICR 142LAQ is one of CLGs state-of-the-art ISOCRACKING catalysts. This catalyst effectively upgrades the VGO
to high quality products. The catalyst is used in the first stage and has a high selectivity for conversions to middistillates. In addition, its high activity inhibits coke formation resulting in longer catalyst life.
Denstone Support (Inert Spheres) is used at the bottom of each bed to support the active catalyst above and
prevents the smaller diameter active catalyst from migrating toward the catalyst internals and catalyst support
tray where they can cause plugging and pressure drop buildup.
Second-Stage HCR
ICR 240L is another of CLGs state-of-the-art ISOCRACKING catalysts. This catalyst effectively upgrades the feeds
to high quality products. The catalyst is used in the second-stage reactors and has a high selectivity for
conversions to mid-distillates. In addition, its high activity inhibits coke formation re sulting in longer catalyst life.
DHT Section
ICR 308QF is an active HDM catalyst that preserves the activity of downstream catalyst, especially against silicon
poisoning. ICR 308 is ideally suited for coker feedstocks. This layer of catalyst is commonl y referred to as the
silicon guard bed.
ICR 154LF is a high activity hydrotreating catalyst that performs deep HDS and HDN. It converts sulphur and
nitrogen in the feed into H2 S and NH3 .
Reactor Temperature Profile

HCR reactions release a large amount of heat, causing the catalyst temperature to rise. The higher temperature
promotes the cracking reactions, thereby releasing even more heat. This sequence of events must be controlled to
prevent the temperature from approaching the reactor design temperature. The primary function of the quench
system is to control the extent of reaction (rate of heat release) and the temperature rise across each bed. The
quench controllers monitor the temperature at the top of each bed and regulate the flow of quench gas above each
bed. The bed heights are chosen to give approximately equal heat release per catalyst bed, provided each bed is
operated at the same average temperature.
Four important terms should be defined before further discussion of reactor temperature profiles:
Level Average Temperature (LAT)

Bed Average Temperature (BAT)
Catalyst Average Temperature (CAT)
Temperature Profile
The LAT is the simple arithmetic average for a set of thermocouples at one level in a catalyst bed. The BAT is the
simple arithmetic average of the bed inlet and outlet LATs. The CAT is the weighted average of the BATs. Each
individual BAT is weighted by the volume fraction of the total active catalyst in that bed. The temperature profile
describes the BATs for the whole reactor. There are three types of profiles:
A flat temperature profile means that the BATs are equal.
An ascending profile means that each successive BAT is higher than the bed above.
A descending profile means that each successive BAT is lower than the bed above. This profile is rarely used (or
achievable).
BAT, CAT, and temperature profiles are all used to monitor reactor performance. The CAT determines how hard the
catalyst is working and the temperature profile describes how the work is distributed over the reactor. A flat profile
will cause the catalyst work to be evenly distributed in the reactor, which maximizes the catalyst life and liquid yields.
A rising profile will cause less burden on the upper beds and more burden on the lower beds. As a result, the upper
beds foul slower and the lower beds foul faster than normal. The overall effect is a somewhat reduced catalyst life
compared to when running a flat profile.
Some refiners choose to run a rising profile because in some cases the reduced utilities costs are worth more than the
increased catalyst costs. A rising profile saves utilities for two reasons:
The reaction heat release is not quenched as hard so the recycle compressor flow rate (which includes quench gas)
decreases, and hence its horsepower goes down.
The increased difference between reactor inlet and outlet temperatures enables the feed/ effluent exchangers to
transfer more heat, allowing the furnace firing rate to be reduced.
Please note that running a rising profile does not affect the amount of heat contained in the reactor effluent--it just
makes it available at a higher temperature because of the reduced quench gas flow. In effect, less heat is wasted in
the REAC. The heat saved is transferred in the feed/effluent exchanger to reduce the furnace firing rate.
The feed/effluent exchangers can deliver extra heat to the reactor feed by closing the bypass. The feed furnace firing
rate will automatically cut back to hold reactor inlet temperature. When adjusting the bypass rate to recover more
heat from the reactor effluent, remember that the reactor feed furnace should have a minimum temperature rise of
28C. This minimum temperature rise gives the operators the capability of quickly reducing reactor inlet temperature
by shutting down the furnace in case of emergency.
GENERAL CHEMISTRY IN HCU/DHT

Hydrocarbon Group Types
Hydrocarbons are classified into four major groups according to the types of carbon -carbon bonds they contain. The
four major groups are paraffins, naphthenes, aromatics, and olefins. Each group is described below.
Paraffins (alkanes) are straight-chain or branched-chain hydrocarbons without any rings or double bonds.
Straight-chain paraffins are called normal paraffins and are responsible for the waxy character of many petroleum
stocks. Normal paraffins, although having good burning properties, have very high freeze points and very high pour
points, so they make poor jet or diesel fuels. Although they have a very high viscosity index, which is necessary for a
high quality lube oil, their very high pour points make them unsuitable for lube base stocks.
Branched-chain paraffins are called isoparaffins. They make excellent high smoke point, low freeze point jet fuel.
Likewise, they make excellent diesel fuel, having low pour points with high cetane number. They also retain much of
the high viscosity index character of their normal paraffin cousins, but can have very low pour points, so they can
make excellent lube base stock.
H
H
H
H C H
H C H
C
H C H
Normal Paraffin
H
C
H
Isoparaffin
Naphthenes (cyclic alkanes) are saturated ring compounds--they do not contain any unsaturated (benzene-like) rings.
The simplest naphthene is cyclohexane. Its structure is six carbon atoms in a ring, each atom bonded to two hydrogen
atoms. In VGOs or hydroprocessed VGOs, naphthenes are typically six-membered rings. Five-membered rings are also
present but in much lower concentration. Naphthenes have intermediate API gravities and burning properties. The
great majority of molecules in mineral oil-based lube oils contain one or more naphthenic rings plus one or more
paraffinic (alkyl) chains. This class of compounds is called alkyl naphthenes.
C
C
C
H
Naphthenic Compound
(Cyclohexane)
Aromatics contain one or more unsaturated six-member carbon rings. An unsaturated ring contains the equivalent of
three double bonds. If some of the rings share two or more carbon atoms, they are called condensed rings or
polycyclic or polynuclear aromatics. In hydrocrackers, aromatics are generally saturated (hydrogen added) to form
naphthenes. However, at higher temperatures, this trend can be shifted and aromatics can form from naphthenes by
giving up hydrogen.
H
H
H
H
C
C
C
C
C
C
C
C
C
C
C
C
C
H
Polycyclic Aromatic
(Phenanthrene)
Aromatic Compound (Benzene)

(Benzene)
As a group, aromatics have higher carbon-to-hydrogen ratios than any other group. They have relatively low API
gravities and tend to produce smoke when burned, so they make poor jet fuel. They also have lower cetane numbers,
so they make poor diesel fuel. Low molecular weight aromatics have good antiknock properties, however, so they
make excellent high octane gasoline.
Large, condensed aromatic ring structures like pyrene or coronene are believed to be typical precursors to coke
formation on catalyst surfaces which can lead to catalyst deactivation.
Olefins (alkenes) are reactive molecules which contain one or more double bonds in an otherwise paraffinic structure.
Due to their highly reactive character, olefins do not occur naturally in crude oil. Olef ins can be formed as reaction
intermediates during hydrocracking, but the combination of their reactivity plus the environment in a typical
hydroprocessing reactor (high hydrogen partial pressure) is usually sufficient to saturate any olefins before they e xit
the reactor.
H
C
H
Olefin (Butene)
In petroleum-based stocks, heteroatomic compounds are usually hydrocarbons containing nitrogen or sulphur atoms.
Although a feed may contain as much as 3.62 wt % S and 1800 ppmw N present as heteroatoms, a hydrocracker will
almost completely desulphurize and denitrify the product.
Heteroatomic Compounds
H
C
N
H
Pyrrole
C
S
Thiophene
Hydrocracking Reactions
Primary reactions occurring in the hydrocracker are desulphurisation, denitrification, olefin and aromatics saturation,
and hydrocracking. All of these reactions are exothermic. The following paragraphs present a brief discussion of these
reactions.
In desulphurisation and denitrification reactions, sulphur and nitrogen molecules are cleaved from sulphur- or
nitrogen-containing hydrocarbon rings by saturation of the ring and hydrogenation to yield H2S and NH3.
Hydrocracking reactions conserve rings to a greater extent. Occasionally, there are more product molecules with rings
than feed molecules. Paraffins in the final product tend to be branched chains with only minor amounts of normal
paraffins. Olefins are very reactive; therefore, their saturation occurs early in the progress of the reactants through
the reactor.
Desulphurisation
CH
HC
CH + 4H 2
R
Catalyst
CH3
CHCH 2CH3+ H2S
S
Thiophene
Branched Paraffin
R
R
CH
SH + H2
Catalyst
Thiol
CH2
R + H2S
Straight-Chain
Paraffin
Denitrification
RCH2 CH2CH2 NH2 + H2
RCH2CH2CH3 + NH3
Catalyst
Amine
Paraffin
Ammonia
Olefin Saturation
RCH2CH=CH2 + H2
RCH2CH2CH3
Catalyst
Olefin
Paraffin
Aromatics Saturation
H
H
C
H H
C
H
H + 3H 2
C
H
C
H
Aromatic
H H
Naphthene
Hydrocracking: As practiced, hydrocracking is a way to reduce the boiling range and remove heteroatoms (mainly
sulphur and nitrogen) from a feedstock, typically a VGO. If the entire feedstock is to be conve rted into lower boiling
components (extinction recycle), large paraffinic molecules must be cracked into smaller molecules. Alkyl aromatics
also react in the reaction stage to give three types of products:
Aromatic saturation to give a naphthene.
Aromatic dealkylation to give a paraffin and aromatic piece.
Aromatic condensation to give a polycyclic aromatic.
Paraffins and naphthenes experience the breaking of carbon-carbon bonds, generating smaller molecules, usually
paraffins and isoparaffins that have a lower boiling point. Thus, high boiling, less valuable molecules are cracked into
more valuable, lighter boiling range products.
5 Koigawachi Structues-2
Demetalization
(Metals Removal From Feed)
EASY
Olefin Saturation
(Destroy Double Bond With H2)
Desulphurisation
(Sulphur Removal From Feed)
S + H2 H2 S
Denitrification
(Nitrogen Removal From Feed)
N + H2 NH3
Aromatics Saturation
Cracking
(Lower Boiling Point
C12
C8 + C4
H2
HARD
Catalyst Deactivation
During hydrocracker operation, the catalysts will gradually deactivate or foul, losing their ability to promote the
desired reactions. Fouling results from carbonaceous deposits on the catalyst and by metal deposits from trace
contaminants in the feed which block access of the feed molecules to the reaction sites. Catalysts deactivated by
carbonaceous deposits (coke) can be regenerated, but catalysts deactivated by trace metal contaminants are not
regenerable. Some of these known contaminants are volatile Ni and V, although the list is not limited to these
elements. Also, some contaminants could originate from feed additives, such as silicon, or from corrosion products
such as iron sulfide. These contaminants must be minimized and controlled such that the desired catalyst life can be
achieved.
To offset the loss of reaction sites, the reactor temperature must be increased. Higher temperatures raise the rate of
reaction at the remaining sites so that hydrocracking and hydrotreating remains at the desired level. The rate at which
temperature must be increased to compensate for loss of catalyst activity is called the "fouling rate." The fouling rate
is initially high, levels off, and finally increases again near the end of a run. The shape for this tem perature versus time
curve is the result of simultaneous coke and contaminants fouling during a run.
Catalyst Sulfiding
Fresh catalyst must to be sulfided so that the optimum catalyst stability and activity can be obtained before oil feed is
introduced. The sulfiding process consists of catalyst pretreatment with a sulfiding agent in the presence of hydrogen.
When heated and passed over the catalyst, the sulfiding agent breaks down into H 2 S, which reacts with the metal
oxides on the catalyst, thereby generating active metal sites (metal sulfides).
The reactions taking place during sulfiding are as follows:
(1) Cracking of DMDS (the sulfiding agent)
CH3-S-S-CH3 + 3H2 2CH4 + 2H2S
This occurs at temperatures between 218-232C for DMDS.
(2) Conversion of metal oxide to metal sulfide
2H2S + 3NiO + H2 Ni 3S2 + 3H2 O
2H2S + MoO3 + H2 MoS2 + 3H2 O
PROJECT REPORT #1
PERFORMACE EVALUATION OF HCU FRACTIONATOR FEED FURNACE
Problem Statement: To evaluate the thermal efficiency and performance characteristics of
the HCU fractionator feed furnace and its dependencies on various parameters.
MR.
Fractionator Feed Furnace (16-FF-OO-501)

The fractionator feed furnace provides heat input to separate the distillate and unconverted oil from the lighter
products. The tubes in the radiant section are specified as 347 stainless steel. Each tube passes has multiple skin
thermocouples to permit monitoring of tube temperatures and provide warning of poor firing patterns or the need for
tube decoking or pigging.
Furnaces are potentially the most hazardous pieces of equipment in the unit because they contain explosive gas
(hydrogen and hydrocarbons) at high temperature and pressure in close proximity to fire. As a consequence, safety is
carefully considered in their design. The key point is to keep the tube skin temperatures as low as possible by
maintaining a uniform heat flux, by avoiding flame impingement on the tubes, and by maintaining flow through the
tubes at all times. The HCU Fractionator Feed Furnace (16-FF-00-501) is a twin cell cabin type heater. Heater is
designed with four pass coil arrangement, dual fired, horizontal tube type with radiant and convection section. This is
a balanced draft furnace, provided with two forced draft fan & one induced draft fan.
AIR PRE HEATER DESCRIPTION

The Air Pre-heater has been designed by Engineers India Limited, New Delhi, fabricated and supplied by Kamal
Engineering Corporation, Yamuna Nagar. The heat exchange surface in the Air Preheater consists of Cast Iron Tubes
and Glass Tubes.
The Cast Tube Air Preheater module is an assembly of rectangular cast tubes. The cast iron tubes have integral fins on
both internal and external surfaces. The entire tube assembly is built inside a steel frame made by beams and fully
insulated casings. Flue gas and air terminal connections are made of rectangular flanges formed from rolled steel
sections and forms an integral part of the Air Preheater frame. The entire Air Preheater assembly can be considered as
part of ducting system because of its general arrangement. The tube is made up of two half sections, cast
independently and then bolted together. To prevent air leakage in the longitudinal direction two grooves have been
provided on the flanges on either side. Gaskets are placed in the grooves before bolting. The flanges provide the
necessary gap for peripheral grooves on all four sides to accommodate the gaskets to ensure air lightness between
adjacent tubes.
The Glass Tube Air Preheater module is a rectangular box containing Glass Tubes held by tube sheets on both ends.
The two sides of box are blanked with metal cover while the remaining two sides are used as in let/outlet for flue gas.
Flue gases enter at the top of the hot block and flow vertically down over the outside of Cast/Glass Tubes in series and
leave the Air Pre-heater at the bottom of Air Pre-heater. Air enters the Air Pre-heater on one side of the Glass Air Preheater module and flows horizontally through the glass tubes and then cast tubes and leaves the air pre -heater.
Combustion air required for the heater is fed by the two Forced draft fans and is preheated in the outboard Cast and
Glass air Preheater. The air is preheated in Glass Tube Air Preheater up to 98.7C and then in the Cast Tube Air
Preheater up to 299.5C before entering the burners.
Flue Gases from the convection section of the heater first enter the cast APH at 380C and are cooled up t o 206C. The
flue gases then enter into the Glass Tube Air Preheater and are further cooled down to 160C. The cold flue gas from
the APH then enters ID fan and finally leaves through a stack.
In the event of failure of the ID fan the Flue gas bypass stack damper will open fully and the flue gases are vented
directly through the top mounted stack by natural draft.
Forced draft (FD) fans are used to supply combustion air to the burners. They draw ambient air and force it to the
burner system via CAPH/GAPH for the combustion of fuel. Induced draft (ID) fan is used to pull the flue gas from the
heater and discharge it to atmosphere via CAPH/GAPH.
Balanced-Draft: When both forced-draft and induced-draft fans are used with a fired heater, the combination is
known as a balanced-draft system. Most air preheating installations are, in fact, balanced draft.
In a typical air preheating system, the draft loss across the air preheater could be on the order of 200 mmWC. The
stack by itself cannot compensate for a loss of this magnitude. Instead, the FD fan supplies the combustion air, and the
ID fan takes care of flue gas disposal. In these systems, draft control is require d for efficient combustion.
FURNACE EFFICIENCY
The efficiency of a furnace is the ratio of useful output to heat input. The furnace efficiency here has been determined
by indirect method and approximated by a thumb rule.
The energy required to increase the temperature of a material is the product of the mass, the change in temperature
and the specific heat. i.e. Energy = Mass x Specific Heat x rise in temperature. The specific heat of the material can be
obtained from a reference manual and describes the amount of energy required by different materials to raise a unit
of weight through one degree of temperature.
If the process requires a change in state, from solid to liquid, or liquid to gas, then an additional quantity of energy is
required called the latent heat of fusion or latent heat of evaporation and this quantity of energy needs to be added to
the total energy requirement.
The total heat input is provided in the form of fuel or power. The desired output is the heat supplied for heating the
material or process. Other heat outputs in the furnaces are undesirable heat losses.
The various losses that occur in the fuel fired furnace are listed below:
1.
2.
3.
4.
Heat lost through exhaust gases either as sensible heat or as incomplete combustion.
Heat loss through furnace walls and hearth.
Heat loss to the surroundings by radiation and convection from the outer surface of the walls.
Heat loss through gases leaking through cracks, openings and doors.
INDIRECT METHOD FOR CALCULATION OF EFFICIENCY

Furnace efficiency is calculated after subtracting sensible heat loss in flue gas, loss due to moisture in flue gas, heat
loss due to openings in furnace, heat loss through furnace skin and other unaccounted losses from the input to the
furnace.
In order to find out furnace efficiency using indirect method, various parameters that are required are hourly furnace
oil consumption, material output, excess air quantity, temperature of flue gas, temperature of furnace at various
zones, skin temperature and hot combustion air temperature. Efficiency is determined by subtracting all the heat
losses from 100.
Measurement Parameters
The following parameters were used in calculation of furnace efficiency by indirect method:
Flue Gas Analysis

Fuel Gas Analysis
Flue Gas And Air Temperature After Preheater
Furnace Skin Temperature
Calorific Value Of Fuel
Calculated Parameters
The following parameters were calculated for determination of furnace efficiency by indirect method:
Weighted average Cp of flue gas.
Mass ratio of components in fuel gas and stoichiometric O 2 required to combust them.
Excess air for combustion .
Sensible Heat Loss in Flue Gas:
(Where O is the % of oxygen in flue gas)

2
Theoretical air required to burn 1 kg of oil= X

Total air supplied = Theoretical air x (1 + excess air/100)
Sensible heat loss = m x C x T

p
(m = Weight of flue gas)

= Actual mass of air supplied / kg of fuel + mass of fuel (1kg)
C = Specific heat of flue gas
p
T = Temperature difference
% Heat loss in flue gas = Sensible Heat Loss x 100/GCV of fuel
Loss Due to Evaporation of Moisture Present in Fuel
Where,
M - % Moisture of in 1 kg of fuel oil (Here, there is no moisture in the fuel- indicated by analysis report)
T - Flue Gas Temperature
fg
amb
- Ambient temperature
GCV - Gross Calorific Value of Fuel
Loss Due to Evaporation of Water Formed due to Hydrogen in Fuel
Where, H % of H in 1 kg of fuel oil

2
Heat Loss through Skin:

The quantity of heat loss from surface of furnace body is the sum of natural convection and thermal radiation. This
quantity can be calculated from surface temperatures of furnace. The temperatures on furnace surface should be
measured at as many points as possible, and their average should be used. If the number of measuring points is too
small, the error becomes large.
The quantity (Q) of heat release from a reheating furnace is calculated with the following formula:
Q: Quantity of heat release in kCal / W / m

a : factor regarding direction of the surface of natural convection ceiling = 1.9,
side walls = 1.8, hearth = 1
t : temperature of external wall surface of the furnace (C)

l
t : temperature of air around the furnace (C)

2
E: emissivity of external wall surface of the furnace

(As directed by the project guides, radiation losses have been assumed to be negligible)
APPROXIMATE METHOD FOR CALCULATING HEATER EFFICIENCY:
Furnace Efficiency = 100 - (%Oxygen)/2 - (Flue Gas Temperature)/20

Estimated Error= +/- 2%
RESULTS
Using Approximate Method:
1. With Air Preheater:
89.55%
2. Without Air Preheater:
82.05%
Using Indirect Method:

1. Sensible Heat Loss:
2.99%
2. Heat Loss Due To Evaporation of Moisture in Fuel
0.00%
3. Heat Loss Due To Evaporation Of Water
2.03%
4. Heat Loss Due To Convection through Skin
4.50%
Therefore, Furnace efficiency by indirect method:
90.49%
(For detailed calculations please refer to the accompanying spread sheet)
VARIOUS TRENDS IN FURNACE EFFICIENCY

EFFECT OF GROSS CALORIFIC VALUE OF FUEL ON EFFICIENCY
93
92.5
92
91.5
91
Series1
90.5
Poly. (Series1)
90
89.5
89
88.5
88
8000
y = -6E-08x 2 + 0.0023x + 71.46
10000
12000
14000
16000
GCV of
Fuel
Efficiency(%)
10000
88.46
11000
89.51
12000
90.39
13000
91.13
14000
91.76
15000
92.31
The efficiency of the furnace increases with an increase in the Gross Calorific Value of the fuel used. This is
because the same mass of fuel releases more energy and thus fuel requirement is reduced.
This increase is observed to be polynomial(2nd Degree).
EFFECT OF PREHEATED AIR TEMPERATURE ON EFFICIENCY

94
93
92
91
90
Series1
89
88
87
86
85
50
100
Preheated Air
Temperature
40
50
75
100
125
150
170
150
200
Efficiency
85.53
86.14
87.65
89.16
90.67
92.19
93.4
This graph shows the rationale behind the air preheater setup used. Heat energy, which would otherwise be
wasted by dissipation into the environment, is used to pre heat the air entering the combustion chamber.
When the flue gas exit temperature equals the pre heated air temperature, we can say that maximum heat
recovery has taken place. If preheated air temperature is lower than the flue gas exit temperature, we can say
that some energy that could be reclaimed has been wasted (on the left of the peak). Thi s will lead to additional
fuel requirements therefore reduced efficiency. No values towards the right of the peak are practically
possible in the given set up, as the heating utility cant heat the cold stream beyond its own temperature.
EFFECT OF FLUE GAS TEMPERATURE ON EFFICIENCY

94
92
90
Series1
88
Linear (Series1)
86
y = -0.0605x + 106.75
84
82
120
170
220
270
220.8
225
250
275
300
325
350
375
400
EFFICIENCY
93.4
93.14
91.63
90.12
88.61
87.09
85.58
84.07
82.56
FLUE GAS
TEMPERATURE
320
370
420
This graph emphasizes how air preheater helps in maximizing the efficiency of the set up. When the flue gas
exit temperature equals the pre heated air temperature, we can say that maximum heat recovery has taken
place. If we let hotter flue gas escape, we end up with reduced efficiency as we let excess heat energy
dissipate into the environment (on the right of the peak). This will lead to additional fuel requirements
therefore reduced efficiency. No values left of the peak are practically possible in the given set up, as the
cooling utility cant cool the hot stream beyond its own temperature.
OBTAINING DATA
Fuel gas analysis was obtained from the analysis performed by the Quality Assurance Laboratory, BORL.
Procedure, formulae and co-efficients obtained from the Energy Performance Assessment Of Furnaces
document of the Bureau of Energy Efficiency (BEE).
Flue gas composition obtained from Operating Manual for Furnaces Volume-II, HCU/DHT, BORL.
Real time temperature data from the HCU-DCS(Digital Control System) at the MCR (Main Control Room) panel.
Project Report #2
MODELLING AND SIMULATION OF HEAT EXCHANGER NETWORK
PROBLEM STATEMENT: Modelling the existing heat exchanger network and simulating
alternative design cases using pinch analysis in order to determine optimum positioning of
feed gas line to minimize the cost of utilities and heat exchangers.
MR.
PRINCIPLES OF PINCH ANALYSIS

Most Industrial processes involve heat transfer from one process stream to another process stream (interchanging) or
from a utility stream to a process stream. In the present energy crisis scenario, target in any industrial process is MER
Maximum Energy Recovery or Minimum Energy Requirements.
The term Pinch Technology was introduced by Linhoff and Vredeveld to represent a new set of thermodynamically
based methods that guarantee minimum energy levels in design of heat exchanger networks. It also ensures
minimizing the capital costs and fewer emissions.
Pinch Technology represents a simple methodology for systematically analyzing chemical processes and the
surrounding utility systems with the help of the First and the Second Law of Thermodynamics.
1st Law of Thermodynamics: Provides the energy equation for calculating the enthalpy changes (H) in the streams
passing through a heat exchanger.
2nd Law of Thermodynamics: Determines the direction of heat flow. That is, the heat energy may only flow in the
direction of hot to cold. This prohibits temperature crossovers of the hot and cold stream profiles through the
exchanger unit.
In practice the hot stream can only be cooled to a temperature defined by the temperature approach of the heat
exchanger. The temperature approach is the minimum allowable temperature difference (Tmin) in the stream
temperature profiles, for the heat exchanger unit. The temperature level at which Tmin is observed in the process is
referred to as the pinch point or pinch condition. The pinch defines the minimum driving force allowed in the
exchanger unit. Thus, the prime objective of pinch analysis is to achieve financial savings by better process heat
integration (maximizing process-to-process heat recovery and reducing the external utility loads).
The point where Tmin occurs is known as the Pinch. Once the pinch has been identified, it is possible to consider
the process as two separate systems: one above and one below the pinch as shown in the figure.
The system above the pinch requires a heat input and is therefore a net heat sink. Below the pinch, the system rejects
heat and so is a net heat source.
To summarize, the understanding of the pinch gives three rules that must be obeyed in order to achieve the minimum
energy targets for a process:
Heat must not be transferred across the pinch, i.e., no temperature crossovers.
There must be no external cooling above the pinch.
There must be no external heating below the pinch.
CASES CONSIDERED
ORIGINAL CASE
Number Of Heat Exchangers Required: 1 below the pinch + 3 above

the pinch.
Hot Utility Required: 1159573 kJ/s
Pinch Temperature: 349 C
ALTERNATIVE DESIGN CASE 1
Number Of Heat Exchangers Required: 1 below the pinch + 3 above the pinch.
Cold Utility Required: 1371840 kJ/s above the pinch.
72226200 kJ/s below the pinch.
Pinch Temperature: 387.97 C DTmin: 55.9 C
ALTERNATIVE DESIGN CASE 2
Number Of Heat Exchangers Required: 1 below the pinch + 3 above the

pinch.
Cold Utility Required: 1371840 kJ/s above the pinch.
86507880 kJ/s below the pinch.
Pinch Temperature: 387.97 C DTmin: 55.9 C
RESULTS
Comparing the three cases:
We require the same amount of heat exchangers in all the three cases, but the minimum amount of heat
exchange takes place in the original case-this means that the exchangers will have a lower total area required
for exchange and therefore lower exchanger costs.
Total amount of utilities is much lower in the original case, significantly higher in the second case and the
highest in the third case.
Therefore, we infer that the original design of the heat exchanger network is the most optimized among the
three cases studied above.
OBTAINING DATA
Stream Data and Furnace heat load obtained from HCU/DHT Process Manual, BORL.
Pinch Analysis performed and all pinch diagrams generated by PinchLENI 3.0.
Project Report #3
PERFORMANCE EVALUATION OF 1st STAGE REACTOR EFFLUENT/DHT FEED HEAT
EXCHANGER
Problem Statement: To evaluate the efficiency of a counter-current heat exchanger and to
plot its dependencies on various parameters.
MR.
HEAT EXCHANGER
Heat exchange is the science that deals with the rate of heat transfer between hot and cold bodies. Transfer of heat to
and from process is an essential part of most chemical process. i.e. Transferring heat from one fluid to another
through a metal wall. The fluids involved may both be liquids, may both be gases or the case may be one of heat
transfer from a liquid to a gas or vice versa. A common case is that of transferring heat from condensing steam to a
liquid. A Heat Exchanger is an equipment which effects such a transfer. The most important type of heat transfer
equipment is a shell and tube heat exchanger. The general function of a heat exchanger is to transfer heat from one
fluid to another. The basic component of a heat exchanger can be viewed as a tube with one fluid running through it
and another fluid flowing by on the outside. There are thus three heat transfer operations that need to be described:
1. Convective heat transfer from fluid to the inner wall of the tube,
2. Conductive heat transfer through the tube wall, and
3. Convective heat transfer from the outer tube wall to the outside fluid.
CLASSIFICATION OF HEAT EXCHANGER

According To Services: The heat exchanger in question is classified as follows1) Exchanger: It is a unit that Exchanges heat between two process streams without phase change i.e. Liquids are not
evaporated nor condensed.
2) Cooler: Cools process stream without phase change.
3) Preheater: Used to preheat incoming streams in order to reduce load on the main heater.
Recuperative Heat Exchangers:

A recuperative exchanger is equipped with separate flow conduits for each fluid. (As opposed to regenerative heat
exchangers, where only a single set of flow channels through a relatively massive solid matrix. The hot and cold fluids
pass through the matrix alternatively.)The fluids flow simultaneously through the heat exchanger in separate paths,
and heat is transferred from the hot fluid to cold fluid across the walls of the flow section. Among recuperative heat
exchangers, the exchanger in question is classified as followsTubular Heat Exchanger.
Tubular Heat Exchangers:

Tubular heat exchanger consists of tube within tube in different arrangement to carry out effective heat transfer
between two fluids flowing through them. Among these, the given heat exchanger is classified asShell - And - Tube - Exchanger:
It consists of a bundle of tubes encased in a shell. Heat transfer takes place in between the liquids flowing through the
shell and that through the tubes. It is common form of multi-tubular heat exchange r where capacity is increased, tube
length is reduced and more than one internal tube is incorporated within the outer tube enclosure. It is widely used in
industry for liquid / liquid heat transfer, for liquid / condensing - vapour applications, and for liquid / evaporatingvapour systems. It is inexpensive, easy to clean, available in many sizes and high range of operating pressure.
Flow Arrangement:
A variety of shell side and tube side flow arrangement are used in industry to have compromise among number of
factors such as the maximum temperature difference between the fluids (LMTD), manufacturing techniques and cost,
pressure drop, friction effects, and fouling of heat exchanger surface by the precipitation of sediments or
polymerization.
The current flow configuration is Counter Current Flow: The two fluid streams enter together at different direction,
flow in opposite direction and leave at different end. i.e. Fluid on the shell side flows longitudinally over the tubes in
the direction opposite the flow of fluid inside the tubes. In this arrangement the temperature differential between the
fluids is a minimum, and very high thermal effectiveness can be achieved.
CALCULATIONS
Figure: Concentric Cross-current heat exchanger( Here, b-> Hot stream, a-> cold stream)
where,
where,
where h0 is the overall heat transfer coefficient.
And, q=Q/A.
Input Parameters:
Mass Flow Rate of Cold Stream:
Mass Flow Rate of Hot Stream:
Inlet Temperature of Cold Stream:
261164
302608
349
Outlet Temperature of Cold Stream:

Inlet Temperature of Hot Stream:
Outlet Temperature of Hot Stream:
Specific Heat of Cold Stream:
Specific Heat of Hot Stream:
External Diameter of the Exchanger
Tube:
Length of the Exchanger Tube:
Number of tubes in the exchanger:
360
417
408
0.87049
1.02581
19.05 mm
3658 mm
Straight Line
1348
Therefore, % Efficiency of 1st stage reactor effluent/DHT feed exchanger is: 73.175%
VARIOUS TRENDS IN HEAT EXCHANGER EFFICIENCY

VARIATION OF HEAT EXCHANGER EFFICIENCY WITH AREA OF HEAT EXCHANGE
100
90
80
70
60
Series1
50
Poly. (Series1)
40
30
y = 6E-05x2 - 0.1227x + 104.76
20
200
400
600
800
1000
1200
Area
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
450
475
500
750
1000
Efficiency
98.916
96.617
93.789
90.82
87.877
85.03
82.31
79.723
77.27
74.95
70.754
70.674
68.703
66.835
65.063
63.38
61.778
60.254
58.802
47.352
39.615
We infer that if we are to achieve the same amount of heat transfer(keeping heat load unchanged) with a
smaller area available for heat exchange, we need a more efficient heat exchanger.
In practise, heat exchanger efficiency is independent of the total area of heat exchange as the total amount of
heat exchanged also increases with an increase in total are of heat transfer, thus keeping the efficiency
constant.
A more efficient heat exchanger will have a lower area requirement but higher fabrication cost. Therefore, an
optimum balance between heat exchanger efficiency and total tube are a has to be found out(at a desired heat
load).
The desired efficiency of the heat exchanger varies with the heat exchanger efficiency polynomially(2nd
Degree).
VARIATION OF HEAT EXCHANGER EFFICIENCY WITH OUTLET TEMPERATURE OF HOT STREAM

100
90
80
70
60
y=
-0.071x 2 + 55.33x -
10686
50
Series1
40
Poly. (Series1)
30
20
10
0
415
410
405
400
395
390
385
Outlet Temperature of Hot

Stream
Efficiency
410
58.9
405
73.24
400
81.26
395
86.3
390
89.7
As the Th increases, heat duty of the heat exchanger also increases. Thus, we require a more efficient heat
exchanger to cool the hot stream( or heat the cold stream) more than the current set up.
This variation is found to be roughly polynomial(2nd Degree).
A similar curve can be obtained by varying the cold stream outlet temperature, causing a change in the heat
load.
VARIATION OF HEAT EXCHANGER EFFICIENCY WITH MASS FLOW RATE OF HOT STREAM
105
95
85
75
65
55
45
35
25
200000 300000 400000 500000 600000 700000 800000
Series1
Mass Flow Rate of Hot

Stream
Efficiency
200000
35.89
250000
67.04
300000
65.58
350000
70.16
400000
74.78
450000
78.91
500000
82.48
550000
85.52
600000
88.07
650000
90.21
700000
91.99
750000
93.46
As a general trend, a more efficient heat exchanger is required to achieve the same Th when mass flow rate of
hot stream is increased keeping the mass flow rate of cold stream constant. This is because more amount of
heat is to be removed by the same amount of cooling stream, requiring more efficient heat transfer.
OBTAINING DATA
Design data including the size and number of tubes in the exchanger was obtained from General Arrangement
Drawings of the 1st Stage Reactor Effluent/DHT Feed Heat Exchanger.
Inlet and outlet temperatures and specific heat values of both streams were obtained from the Stream Data,
HCU/DHT Process Manual, BORL.

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Bharat Oman Refineries Limited

Kunal Parwani Internship Report

A PROJECT REPORT ON FRACTIONATOR FEED FURNACE AND REACTOR

PROJECT REPORT SUBMITTED IN FULFILMENT OF SUMMER INTERNSHIP

BHARAT OMAN REFINERIES LIMITED

Bharat Oman Refineries Limited

Kunal Parwani Internship Report

This is to certify that the training report entitled FRACTIONATOR FEED

Mr. SANJEEV VERMA

Mr. A.P. RAGHAV

ASST. VICE PRESIDENT

BORL, BINA, M.P.

BORL, BINA, M.P.

BORL, BINA, M.P.

Bharat Oman Refineries Limited

Kunal Parwani Internship Report

Bharat Oman Refineries Limited

Kunal Parwani Internship Report

Bharat Oman Refineries Limited

Kunal Parwani Internship Report

Bharat Oman Refineries Limited

Kunal Parwani Internship Report

INTRODUCTION TO BINA REFINERY

The project has followings facilities.

Primary Processing facilities:

Crude Distillation Unit(CDU)

Vacuum Distillation Unit(VDU)

Secondary Processing Facilities:

Bharat Oman Refineries Limited

Kunal Parwani Internship Report

Motor Spirit Block(MSB)

Delayed Coker Unit(DCU)

LPG Treating unit

Sulphur Recovery Block(SRB)

Hydrogen Generation Unit(HGU)

Captive Power Plant(CPP)

Raw Water intake system

Raw water treatment plant

Cooling Tower and Cooling water treatment plant

Reverse Osmosis based Demineralization (RODM)

Nitrogen plant and Effluent Water Treatment Plant(ETP)

Bharat Oman Refineries Limited

Kunal Parwani Internship Report

The major products of Bina Refinery are:

Liquefied Petroleum Gas(LPG)

Euro III Motor Spirit (MS)

Euro IV Motor Spirit (MS)

Aviation Turbine Fuel(ATF)

Euro III HSD

Bharat Oman Refineries Limited

Kunal Parwani Internship Report

Crude & Vacuum Distillation Unit (CDU/VDU)

Bharat Oman Refineries Limited

Kunal Parwani Internship Report

Integrated Full Conversion Hydrocracker (FCHC) & Diesel Hydrotreater (DHT)

Bharat Oman Refineries Limited

Kunal Parwani Internship Report

Delayed Coker Unit (DCU)

Bharat Oman Refineries Limited

Kunal Parwani Internship Report