REPORT ON SUMMER VOCATIONAL

TRAINING

INDIAN OIL CORPORATION LIMITED

MATHURA REFINERY

PERIOD OF TRAINING
(01st June – 30th JUNE 2018)

Submitted By :

Harsh Ashara
B.Tech Chemical Engineering with specialization in refining and petrochemicals

University of Petroleum and Energy Studies

Dehradun

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 PREFACE

Industrial training is the beginning of students’ journey in the corporate

world. Not only does it provide insights about the industry concerned, it
also bridges the gap between theory and practical knowledge. We were
fortunate that we were provided with an opportunity of undergoing
Industrial training at INDIAN OIL CORPORATION Ltd ., Mathura, one of the
leading refineries in India.

The experience gained during this short period was fascinating to say the
least. It was a tremendous feeling to observe the operation of different
equipments and processes. It was overwhelming for us to not ice how such
a big refinery is being monitored and operated with proper co -ordination
to obtain desired results.

During our training we realized that in order to be a successful process

engineer one needs to possess a sound theoretical base along with the
acumen for effective practical application of the theory.
Thus, we hope that this industrial training serves as a stepping -stone for
us and helps to be successful in future.

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 Acknowledgement

I feel immense pleasure and privilege to express my deep sense of gratitude, indebtedness
and thankfulness towards those who generously helped me colour the mosaic of this training
with their knowledge, expertise and memories. I shall remain ever grateful to all the persons
of I.O.C.L, who have helped, inspired and encouraged me and above all made me an ever
more experienced person.

For their invaluable guidance, kind cooperation, inspiration and encouragement during all
the stages of my training, I would like to thank our co-ordinator Mr. Rajesh Kumar Pandey &
all senior production managers. In spite of their busy schedule, they were always eager to
help us out and share their vast experiences with us. We would also like to heartily thank the
shift engineers and operators who in spite of their arduous task took time out to explain each
and every detail of the processes and also provided us with invaluable technical advices about
every aspect of the plant. We are really thankful to the staff for cooperating with us
immensely. We are thankful to the following departments and their staffs for their insights
on the industry. Last but not least, I would like to convey my hearty and blossom thanks to
my friends and fellow mates who have directly or indirectly helped me in the compilation of
this report.

After the completion 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
regarding the actual work carried out in a Refinery Plant. At the end, I again express my
gratitude to all those who helped me in any way to complete my training successfully

Harsh Ashara

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 INDEX

S.NO. Content Page no.

1. INTRODUCTION 5

2. MATHURA REFINERY & ITS OBJECTIVES 7

3. PRODUCTS AND THEIR SPECIFICATION 9

4. DIESEL HYDRO DESULFURIZATION UNIT (DHDS) 11

5. DIESEL HYDRO-TREATMENT UNIT (DHDT) 13

6. PROJECT: SIMULATION OF PRE-FRACTIONATOR IN ATMOSPHERIC 15

DISTILLATION UNIT USING ASPEN PLUS

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 Introduction

• Present-day refineries produce a variety of products including many required as

feedstock for the petrochemical industry
• The opening of the first refinery two years later to process the crude into kerosene
• The petroleum industry began with the successful drilling of the first commercial oil
well in 1859
• Petroleum refining has evolved from simple distillation to today's sophisticated
processes
• The original requirement was to produce kerosene as a cheaper and better source of
light than whale oil.
• The development of the internal combustion engine led to the production of gasoline
and diesel fuels The evolution of the airplane created a need first for high-octane
aviation gasoline and then for jet fuel, a sophisticated form of the original product,
kerosene
• The first refinery, opened in 1861, produced kerosene by simple atmospheric
distillation.
• Its by-products included tar and naphtha
• It was soon discovered that high-quality lubricating oils could be produced by distilling
petroleum under vacuum.
• However, for the next 30 years kerosene was the product consumers wanted
• Two significant events changed this situation: (1) invention of the electric light
decreased the demand for kerosene, and (2) invention of the internal combustion
engine created a demand for diesel fuel and gasoline

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 INDIAN OIL CORPORATION

Only three decades ago, Indian looked to the world for help in its quest for oil. Then slowly,
but surely the scenario changed. Indian oil corporation ltd.(Estd.1958) with Indian oil
company(Estd.1959)played a leader role in this transformation. Today, Indian oil owns and
operates 6 refineries at Digboi, Guwahati, Haldia, Barauni, Mathura and Gujarate amongst
the country’s twelve refineries, with a combined crude oil refining capacity of over 24 million
tones which is about 47% of the total refining capacity in India. Indian oil’s seventh grassroots
refinery is coming up at Karnal in Haryana with a capacity of 6 million tones per annum. Indian
oil’s first product pipeline in the Guwahati-Siliguri sector carned itself the honors of being the
first petroleum product pipeline to be constructed on the eastern side of suez canal.Indian
oil’s pipeline length progressively grew to today’s level of over 3800 km maintaining an
uninterrupted flow of crude oil to refineries and petroleum products to the consuming
centers across the length and breadth of the country.Currently, Indian oil is executing its
longest ever petroleum product pipeline ,all of 1454 km, originating from Kandla in Gujarat
and terminating at Bhatinda in Punjab.

What’s more, Indian oil reaches a wide spectrum of customers through its marketing wing .it
sells over 32 million tones of petroleum products annually through a country wide marketing
network. Indian oil commands a market share of about 57% on the whole. it is interesting to
note that Indian oil runs a retail outlet at the world’s highest point kaza in Himalayas as
well.Indian oil is the only oil refining and marketing company in India India which has a full
fledged research and development center. nearly 600 of the lubricant formulations
developed at this center have been commercialized thereby indegenising over 95% of the
lubricant marketed by Indian oil. This center has mastered the complete know how of FCC
catalyst evaluations and manufacturing in India with its own formulation apart from giving
support services on fcc’s to Indian refineries.

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 MATHURA REFINERY

Mathura refinery standing bold on the outskirts of Mathura on Delhi-Agra highway, has been
the harbinger of technological advancement in this region in perfect harmony with the
environment. Nurturing technology amidst the greens has been a pioneering experiment of a
modern industry and Mathura refinery takes pride in successfully accomplishing this arduous
task since its inception. A torch bearer of north west India: Mathura refinery has been the
focal point of development in industrial and transportation sector for almost the entire
northwest India since it’s commissioning in Jan 1982. This 7.5 million tone refinery is india’s
latest and most modern refinery. Also, it has the wide adaptability of processing over 30 types
of crude oil. This ranges from indigenous Bombay offshore crude to imported crudes of
Australian origin in the east and Nigeria and Venezuela in the far west. Mathura refinery has
the distinction of having single largest capacity crude distillation unit which has the unique
engineering marvel of 67 m high crude distillation column. The crude to the refinery is
received from salary in west coast through a dedicated cross country 1078km pipeline .
Products from this refinery are dispatched through rail, road and Mathura-Delhi-Ambala-
Jalandhar pipeline .the contribution of Mathura refinery in meeting the petroleum products
demand of north west India is about 68%.

Indian Oil Corporation Limited or IOC is India’s largest commercial enterprise and the only
Indian company to be among the world’s top 200 corporations according to Fortune
magazine. It is also among the 20 large
+st petroleum companies in the world.
It was established in 1959 as Indian Oil Company Limited which was merged with Indian
Refineries Limited in 1964 to form IOC as it is today.
Indian Oil Corporation has four divisions:
 Marketing Division with Headquarters at Bombay;
 Refineries and Pipelines Division with Headquarters at New Delhi;
 Assam Oil Division with Headquarters at Digboi; and
 Research and Development Centre at Faridabad.

Indian Oil Corporation Limited is India's largest commercial enterprise with a turnover of
Rs.2, 85,337 crore and a net profit of Rs.2, 950 crore in 2008-09. Indian Oil alone accounts
for 56 % petroleum product market share among PSU companies, 42% National refining
capacity and 68% downstream pipeline throughput capacity. Indian Oil group owns and
operates 10 of India’s 18 refineries with a current combined rated capacity of 54.2 Million
metric tonnes (MMTPA). These include subsidiaries viz. Chennai Petroleum Corporation Ltd
and Bongaigaon Refinery & Petrochemicals Ltd. It owns and operates the country’s largest
network of cross-country crude and product pipelines, with a combined length of 7,730 km
with a combined capacity of 54.2 MMTPA.

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The LPG bottling plant situated within Mathura refinery premises bottles nearly 7 million
cylinders per annum for catering to domestic market. Major fertilizes industries at Kanpur,
Panipat, Nangal, Bhatinda and Kota are supplied with naphtha or furnace oil/ heavy
petroleum stock as fertilizer feed stocks from Mathura refinery. Also, thermal power plants
of Nangal, Obra and Badarpur get fuel oil supply from this refinery. Apart from this, Mathura
refinery is privileged to provide the necessary energy to the pulsating capital, New Delhi and
also boost the standards of the farmers belonging to the crop rich lands of Punjab and
Haryana. The other important product, bitumen, has paved the transportation sector in this
region on to road worthiness. To keep the environment clean and green. Mathura refinery
recovers nearly 10,000kgs of sulphur everyday as a by-product from crude oil.

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 Objectives

The objectives of the Company as approved (June, 1984) by Government are as follows:
 To serve the national interests in the oil and related sectors in accordance and
consistent with Government policies.
 To ensure and maintain continuous and smooth supplies of petroleum products by
way of crude refining, transportation and marketing activities and to provide
appropriate assistance to the consumer to conserve and use petroleum products
most efficiently.
 To earn a reasonable rate of return on investment.
 To work towards the achievement of self-sufficiency in the field of oil refining, by
setting up adequate domestic capacity and to build up expertise for pipe laying for
crude/petroleum products.
 To create a strong research and development base in the field of oil refining and
stimulate the development of new petroleum products formulations with a view to
one sized/ eliminate their imports, if any and
 To one sized of the existing facilities in order to improve efficiency and increase
productivity.1

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 PRODUCTS AND THEIR SPECIFICATION

The following petroleum products are obtained from crude oil in Mathura
refinery,
1. Liquefied petroleum gas
2. Motor sprit or petrol
3. Naphtha
4. Aviation turbine fuel
5. Kerosene oil
6. High speed diesel oil
7. Light diesel oil
8. Fertilizer feed stock
9. Heavy petroleum stock
10. Bitumen
11. Sulphur

PRODUCT SPECIFICATION:

L.P.G:
1. Copper corrosion at 38ºC for one hour on ASTM copper strip. Max 1b for passing
2. Total volatile sulphur = 0.02%max
3. Vapour pressure at 65ºC = 16.87ºC Kg/cm² gauge.
4. Hydrogen sulfide = absent.
5. Dryness =no free entrained water.
6. Weathering test =83ºC

MOTOR GASOLINE:
1. Colour usually orange
2. Copper strip corrosion for 3 hrs at 50ºC.
3. Octane number = 88RON, 93RON
4. Residue on evaporation = 4mg/100m³.
5. Sulphur total =0.25wt%
6. Vapour pressure at 38ºC = 0.70Kg/cm²
7. Flash point = below 25ºC.

ATF:
1. Appearance =usually clear and bright free from.
2. Flash point = 38ºC
3. Freezing point = -50ºC
4. Smoke point = 20 mm max

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 DIESEL HYDRO DESULFURIZATION UNIT (DHDS):
DHDS (Diesel hydro desulphurization unit) is set up for the following purposes:
 A step towards pollution control
 To produce low sulphur diesel (0.25 w/w %) as per govt. directive w.e.f. Oct. 1999.

Feed consists of different proportion of straight run LGO, HGO, LVGO and TCO. Mainly two
proportions are used:
 74% SR LGO, 21% SR HGO, 5% SR LVGO
 48% SR LGO, 24% SR HGO, 8% SR LVGO, 20% TCO

The DHDS unit treats different gas oils from various origins, straight run or cracked products.
The feed is a mixture of products containing unsaturated components (diolefins, olefins),
Aromatics, Sulfur compounds and Nitrogen compounds. Sulfur and nitrogen contents are
dependent upon the crude.
The purpose of DHDS Unit is to hydro-treat a blend of straight run gas oil and cracked gas oil
(TCO) for production of HSD of sulfur content less than 500 ppm wt.
The Hydrodesulphurization reaction releases H2S in gaseous hydrocarbon effluents. This H2S
removal is achieved by means of a continuous absorption process using a 25% wt. DEA
solution.
In addition to the desulphurization, the diolefins and olefins will be saturated and a
denitrification will occur. Denitrification improves the product stability. The hydrogen is
supplied from the hydrogen unit. Lean amine for absorption operation is available from Amine
Regeneration Unit (ARU). Rich Amine containing absorbed H2S is sent to ARU for amine
regeneration.

CATALYSTS
Catalysts used for this process are HR-945 and HR-348/448.The HR-945 is a mixture of nickel
and molybdenum oxides on a special support. Nickel has been selected because it boosts the
hydrogenating activity. The HR-348 and HR-448 are desulphurization catalysts; it consists of
cobalt and molybdenum oxides dispersed on an active alumna. Its fine granulometry and large
surface area allow a deep desulphurization rate.
Different catalysts based on Nickel and Molybdenum Oxide are used to enhance the rate of
reactions.

Products Yields:

Sl. No. Products wt%

1 Off-Gas 1.36

2 Wild-naptha 1.04

3 Diesel 97.1

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 Diesel Hydro-Treatment Unit (DHDT):

Objective : To meet the EURO-III/IV diesel quality requirement (<350/50 ppmS)

Feed : Straight run diesel / FCC diesel component/ Coker and Visbreaker diesel components.

Catalyst : Ni-Mo oxides

Products Yields:

Sl. No. Products wt%

1 Off-Gas 2.65

2 wild-naphtha 2.8

3 Diesel 96.1

Wild naphtha feed from existing DHDS unit is processed along with DHDT wild naphtha in a
stabilizer located inside DHDT battery limits for producing single naphtha product.

Processes in DHDT:

 Refining & hydrogenation:

Removal of heteroatom (S, N2, O2) Saturation of olefins and dioelfins.

 Hydrodesulfurization:

Hydrodesulfurization reactions are fast and take place in single step.

Mercaptans: R-SH + H2 R-H + H2S

Sulfides: R-S-R + 2H2 2R-H + H2S

 Hydrogenation:

Aromatic saturation & denitrification of heterocyclic compounds.

 Hydrocracking:

Hydroisomerisation & then cracking into lighter isoparaffins.

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  Metal removal
 Coking

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 PROJECT

Simulation of Prefractionator in Atmospheric Distillation Column

Aim: This project aims to simulate the prefractionator of Atmospheric Distillation Column of
IOCL Mathura Refinery using Aspen Plus. Simulation was done to study the compositions (i.e
liquid and vapour) on each tray and also to study the temperature profile.

Introduction: Distillation systems composed of a prefractionator and a main column are

introduced. The columns operate at different pressures, but the temperatures of the utilities
are the same as for a single column performing the same separation. The energy integration
of the columns is realized by condensing a vapour overhead from the prefractionator in an
intermediate reboiler located in the stripping section of the main column or by boiling a
bottoms liquid from the prefractionator in an intermediate condenser placed in the rectifying
section of the main column. Analysis is performed to determine feasible regions of
operational parameters and to minimize vapour flows. A detailed simulation example of the
benzene–toluene separation shows that for certain feed compositions it is possible to reduce
energy requirements of a conventional binary distillation column by almost one‐third using
this new distillation system. This savings is achieved without any change in the temperature
of the utilities used.

Data for the simulation:

Feed Type: Crude ( Basara Light)

Feed Flow rate: 1400 cum/hr

Feed Temperature: 180 Centigrade

Top Pressure: 2.2 kgf/scm

Bottom Pressure: 1.95 kgf/scm

Total number of trays: 45

Feed Tray: 15

Top Temperature: 130 centigrade

Bottom Temperature: 157.5 centigrade

Steam Rate: 5500 kg/hr

Steam Pressure: 13 kgf/scm

Steam Temperature: 303 centigrade

Condenser Temperature: 35 centigrade

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Condenser Pressure: 1.95 kgf/scm

Distillate Rate: 150 cum/hr

Basic outlay:

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Stagewise calculations:

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Temperature profile:

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Composition profile:

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