Muhammad Fahad Ansari 12IEEM14

1. I N T E R N S H I P R E P O R T 2 0 1 0
NATIONAL REFINERY LIMITED KARACHI
GROUP MEMBERS
MEHRAN UET JAMSHORO
INSITUTE OF PETROLEUM AND NATURAL GAS ENGINEERING
• MUHAMMAD FAHAD
• SAJID REHMAN
• SHOAIB MATEEN
NED UNIVERSITY
DEPARTMENT OF CHEMICAL ENGINEERING
• ANUM ZAHID
• SHABHEE ZEHRA
DEPARTMENT OF POLYMER AND PETROCHEMICAL
• NOUSHEEN GHAFFAR
• ASRA NAFEES
DEPARTMENT OF PETROLEUM ENGINEERING
• TABINDA SAEED
UNIVERSITY OF KARACHI
DEPARTMENT OF APPLIED CHEMISTRY
• MUHAMMAD OWAIS

2. • IMMAD HASEEB KHAN
2

3. 3
NATIONAL
REFINERY
LIMITED
INTERNSHIP REPORT OF NATIONAL REFINERY
2010

4. GROUP MEMBERS
MEHRAN UET JAMSHORO
INSITUTE OF PETROLEUM AND NATURAL GAS ENGINEERING
• MUHAMMAD FAHAD
• SAJID REHMAN
• SHOAIB MATEEN
NED UNIVERSITY
DEPARTMENT OF CHEMICAL ENGINEERING
• ANUM ZAHID
• SHABHEE ZEHRA
DEPARTMENT OF POLYMER AND PETROCHEMICAL
• NOUSHEEN GHAFFAR
• ASRA NAFEES
DEPARTMENT OF PETROLEUM ENGINEERING
• TABINDA SAEED
UNIVERSITY OF KARACHI
DEPARTMENT OF APPLIED CHEMISTRY
• MUHAMMAD OWAIS
• IMMAD HASEEB KHAN
4

5. 5
ACKNOWLEDGEMENT
We, thanks to almighty ALLAH the most
merciful. By His grace it made possible to
complete the entire task.
We would also like to thanks the staff of
training center who had supported us a lot and
by their great efforts it was made possible for
us to get the working knowledge specially
respected Mr. Dr. M.Y.K Sanjarani, Mr. Bismillah,
Mr. Bhatti who helped us sincerely in every
respect.
Now, we also mentioning the engineering
department where we had been posted for four
week. They also gave us their precious time and
knowledge and made it easy for us to know the
working scenario overthere.
We would like to thanks all the concerned
working staff of engineering department their
sincere help and guides made it possible to get
2010

6. INTRODUCTION
National Refinery Limited ( NRL ) was incorporated on August 19, 1963 as a public limited
company. Government of Pakistan took over the management of NRL under the Economic
Reforms Order, 1972 under the Ministry of Production, which was exercising control through its
shareholding in State Petroleum Refining and Petrochemical Corporation (PERAC).
The Government of Pakistan had decided to place the National Refinery Limited under the
administrative control of Ministry of Petroleum & Natural Resources in November 1998.
In June 2003 the Government of Pakistan decided to include NRL in its privatisation
programme. The selling of 51% equity and transfer of management control to a strategic
investor had been proposed accordingly, the due diligence process for the privatisation was
initiated. After competitive bidding NRL was acquired by Attack Oil Group in July 2005.
The Company has been privatised and the management handed over to the new owner (Attack
Oil Group) on July 7, 2005.
NRL AT A GLANCE
First Lube refinery 1966
Fuel Refinery 1977
Second Lube Refinery 1985
LIST OF PRODUCTS
• REGULATED
– MOTOR GASOLINE
– KEROSENE
– JP-1
– JP-8
– LDO
– HSD
• DE-REGULATED
– LUBE BASE OILS
– ASPHALTS
– SPECIALITY
– LPG
– NAPHTHA
– FURNACE OIL
6
the task completed

7. GENERAL FLOW SCHEME
7

8. S.No Contents
1. Distillation
2. Vaccum Distillation
3. Boilers
4. Pumps
5. Compressors
6. Furnace
7. Valves
8. Cooling towers
9. Heat Exchangers
8

9. Distillation
Distillation is defined as:
A process in which a liquid or vapour mixture of two or more substances is
separated into its component fractions of desired purity, by the application and
removal of heat.
Distillation is based on the fact that the vapour of a boiling mixture will be richer in the
components that have lower boiling points.
Therefore, when this vapour is cooled and condensed, the condensate will contain more
volatile components. At the same time, the original mixture will contain more of the less
volatile material.
Distillation columns are designed to achieve this separation efficiently.
Although many people have a fair idea what “distillation” means, the important aspects that
seem to be missed from the manufacturing point of view are that:
distillation is the most common separation technique
it consumes enormous amounts of energy, both in terms of cooling and heating
requirements
9

10. it can contribute to more than 50% of plant operating costs
The best way to reduce operating costs of existing units, is to improve their efficiency and
operation via process optimisation and control. To achieve this improvement, a thorough
understanding of distillation principles and how distillation systems are designed is essential.
The purpose of this set of notes is to expose you to the terminology used in distillation practice
and to give a very basic introduction to:
TYPES OF DISTILLATION COLUMNS
There are many types of distillation columns, each designed to perform specific types of
separations, and each design differs in terms of complexity.
One way of classifying distillation column type is to look at how they are operated. Thus we
have:
batch and
continuous columns.
Batch Columns
In batch operation, the feed to the column is introduced batch-wise. That is, the column is
charged with a 'batch' and then the distillation process is carried out. When the desired task is
achieved, a next batch of feed is introduced.
Continuous Columns
In contrast, continuous columns process a continuous feed stream. No interruptions occur
unless there is a problem with the column or surrounding process units. They are capable of
handling high throughputs and are the most common of the two types. We shall concentrate
only on this class of columns.
Types of Continuous Columns
Continuous columns can be further classified according to:
10

11. the nature of the feed that they are processing,
binary column - feed contains only two components
multi-component column - feed contains more than two components
the number of product streams they have
multi-product column - column has more than two product streams
where the extra feed exits when it is used to help with the separation,
• extractive distillation - where the extra feed appears in the bottom product stream
• azeotropic distillation - where the extra feed appears at the top product stream
the type of column internals
tray column - where trays of various designs are used to hold up the liquid to provide better
contact between vapour and liquid, hence better separation
packed column - where instead of trays, 'packings' are used to enhance contact between
vapour and liquid.
BASIC DISTILLATION EQUIPMENT AND OPERATION
Main Components of Distillation Columns Distillation columns are made up of several
components, each of which is used either to tranfer heat energy or enhance materail transfer.
A typical distillation contains several major components:
a vertical shell where the separation of liquid components is carried out
column internals such as trays/plates and/or packings which are used to enhance
component separations
a reboiler to provide the necessary vaporisation for the distillation process
11

12. a condenser to cool and condense the vapour leaving the top of the column
a reflux drum to hold the condensed vapour from the top of the column so that liquid
(reflux) can be recycled back to the column The vertical shell houses the column internals and
together with the condenser and reboiler, constitute a distillation column. A schematic of a
typical distillation unit with a single feed and two product streams is shown below:
Basic Operation and Terminology The liquid mixture that is to be processed is known as the
feed and this is introduced usually somewhere near the middle of the column to a tray known
as the feed tray. The feed tray divides the column into a top (enriching or rectification) section
and a bottom (stripping) section. The feed flows down the column where it is collected at the
bottom in the reboiler.
Heat is supplied to the reboiler to generate vapour. The source of heat input can be any
suitable fluid, although in most chemical plants this is normally steam. In refineries, the heating
source may be the output streams of other columns. The vapour raised in the reboiler is re-
introduced into the unit at the bottom of the column. The liquid removed from the reboiler is
known as the bottoms product or simply, bottoms.
12

13. The vapour moves up the column, and as it exits the top of the unit, it is cooled by a condenser.
The condensed liquid is stored in a holding vessel known as the reflux drum. Some of this liquid
is recycled back to the top of the column and this is called the reflux. The condensed liquid that
is removed from the system is known as the distillate or top product.
Thus, there are internal flows of vapour and liquid within the column as well as external flows
of feeds and product streams, into and out of the column.
COLUMN INTERNALS
Trays and Plates The terms "trays" and "plates" are used interchangeably. There are many
designs, but the most common ones are :
Bubble cap trays
A bubble cap tray has riser or chimney fitted over each hole, and a cap that covers the
riser. The cap is mounted so that there is a space between riser and cap to allow the
passage of vapour. Vapour rises through the chimney and is directed downward by the
cap, finally discharging through slots in the cap, and finally bubbling through the liquid
on
13

14. Valve trays
In valve trays, perforations are covered by liftable caps. Vapour flows lifts the caps, thus
self creating a flow area for the passage of vapour. The lifting cap directs the vapour to
flow horizontally into the liquid, thus providing better mixing than is possible in sieve
trays.
Sieve trays
Sieve trays are simply metal plates with holes in them. Vapour passes straight upward
through the liquid on the plate. The arrangement, number and size of the holes are
design parameter.
Because of their efficiency, wide operating range, ease of maintenance and cost factors, sieve
and valve trays have replaced the once highly thought of bubble cap trays in many applications.
14

15. Liquid and Vapour Flows in a Tray Column
The next few figures show the direction of vapour and liquid flow across a tray, and across a
column.
Each tray has 2 conduits, one on each side, called ‘downcomers’. Liquid falls through the
downcomers by gravity from one tray to the one below it. The flow across each plate is shown
in the above diagram on the right.
A weir on the tray ensures that there is always some liquid (holdup) on the tray and is designed
such that the the holdup is at a suitable height, e.g. such that the bubble caps are covered by
liquid.
Being lighter, vapour flows up the column and is forced to pass through the liquid, via the
openings on each tray. The area allowed for the passage of vapour on each tray is called the
active tray area
15

16. The picture on the left is a photograph of a section of a pilot scale column equiped with bubble
capped trays. The tops of the 4 bubble caps on the tray can just be seen. The down- comer in
this case is a pipe, and is shown on the right. The frothing of the liquid on the active tray area is
due to both passage of vapour from the tray below as well as boiling.
As the hotter vapour passes through the liquid on the tray above, it transfers heat to the liquid.
In doing so, some of the vapour condenses adding to the liquid on the tray. The condensate,
however, is richer in the less volatile components than is in the vapour. Additionally, because of
the heat input from the vapour, the liquid on the tray boils, generating more vapour. This
vapour, which moves up to the next tray in the column, is richer in the more volatile
components. This continuous contacting between vapour and liquid occurs on each tray in the
column and brings about the separation between low boiling point components and those with
higher boiling points.
Tray Designs
A tray essentially acts as a mini-column, each accomplishing a fraction of the separation task.
From this we can deduce that the more trays there are, the better the degree of separation and
that overall separation efficiency will depend significantly on the design of the tray. Trays are
designed to maximise vapour-liquid contact by considering the liquid distribution and
vapour distribution on the tray. This is because better vapour-liquid contact means better
separation at each tray, translating to better column performance. Less trays will be required to
achieve the same degree of separation. Attendant benefits include less energy usage and lower
construction costs.
16

17. Packings
There is a clear trend to improve separations by supplementing the use of trays by additions of
packings. Packings are passive devices that are designed to increase the interfacial area for
vapour-liquid contact. The following pictures show 3 different types of packings.
These strangely shaped pieces are supposed to impart good vapour-liquid contact when a
particular type is placed together in numbers, without causing excessive pressure-drop across a
packed section. This is important because a high pressure drop would mean that more energy is
required to drive the vapour up the distillation column.
Packings versus Trays
A tray column that is facing throughput problems may be de-bottlenecked by replacing a
section of trays with packings. This is because:
packings provide extra inter-facial area for liquid-vapour contact
efficiency of separation is increased for the same column height
packed columns are shorter than trayed columns Packed columns are called continuous-
contact columns while trayed columns are called staged-contact columns because of the
manner in which vapour and liquid are contacted.
17

18. Vacuum distillation
Vacuum distillation is a method of distillation whereby the pressure above the liquid mixture to
be distilled is reduced to less than its vapor pressure (usually less than atmospheric pressure)
causing evaporation of the most volatile liquid(s) (those with the lowest boiling points).[1]
This
distillation method works on the principle that boiling occurs when the vapor pressure of a
liquid exceeds the ambient pressure. Vacuum distillation is used with or without heating the
solution.
Industrial-scale applications
Industrial-scale vacuum distillation[6]
has several advantages. Close boiling mixtures may require
many equilibrium stages to separate the key components. One tool to reduce the number of
stages needed is to utilize vacuum distillation.[7]
Vacuum distillation columns (as depicted in the
drawing to the right) typically used in oil refineries have diameters ranging up to about 14
metres (46 feet), heights ranging up to about 50 metres (164 feet), and feed rates ranging up to
about 25,400 cubic metres per day (160,000 barrels per day).
Vacuum distillation increases the relative volatility of the key components in many applications.
The higher the relative volatility, the more separable are the two components; this connotes
fewer stages in a distillation column in order to effect the same separation between the
overhead and bottoms products. Lower pressures increase relative volatilities in most systems.
A second advantage of vacuum distillation is the reduced temperature requirement at lower
pressures. For many systems, the products degrade or polymerize at elevated temperatures.
Vacuum distillation can improve a separation by:
• Prevention of product degradation or polymer formation because of reduced pressure
leading to lower tower bottoms temperatures,
• Reduction of product degradation or polymer formation because of reduced mean
residence time especially in columns using packing rather than trays.
• Increasing capacity, yield, and purity.
18

19. Another advantage of vacuum distillation is the reduced capital cost, at the expense of slightly
more operating cost. Utilizing vacuum distillation can reduce the height and diameter, and thus
the capital cost of a distillation column.
19

20. Boiler:
A boiler is a closed vessel in which water or other fluid is heated. The heated or vaporized fluid
exits the boiler for use in various processes or heating applications.
Types:
Boilers can be classified into the following configurations:
• Fire-tube boiler.
Here, water partially fills a boiler barrel with a small volume left above to accommodate
the steam (steam space). This is the type of boiler used in nearly all steam locomotives.
The heat source is inside a furnace or firebox that has to be kept permanently
surrounded by the water in order to maintain the temperature of the heating surface
just below boiling point. The furnace can be situated at one end of a fire-tube which
lengthens the path of the hot gases, thus augmenting the heating surface which can be
further increased by making the gases reverse direction through a second parallel tube
or a bundle of multiple tubes (two-pass or return flue boiler); alternatively the gases
may be taken along the sides and then beneath the boiler through flues (3-pass boiler).
In the case of a locomotive-type boiler, a boiler barrel extends from the firebox and the
hot gases pass through a bundle of fire tubes inside the barrel which greatly increase
the heating surface compared to a single tube and further improve heat transfer. Fire-
tube boilers usually have a comparatively low rate of steam production, but high steam
storage capacity. Fire-tube boilers mostly burn solid fuels, but are readily adaptable to
those of the liquid or gas variety.
20

21. • Water-tube boiler
In this type,the water tubes are arranged inside a furnace in a number of possible
configurations: often the water tubes connect large drums, the lower ones containing
water and the upper ones, steam and water; in other cases, such as a monotube boiler,
water is circulated by a pump through a succession of coils. This type generally gives
high steam production rates, but less storage capacity than the above. Water tube
boilers can be designed to exploit any heat source and are generally preferred in high
pressure applications since the high pressure water/steam is contained within small
diameter pipes which can withstand the pressure with a thinner wall.
21

22. Pumps
A pump is a device used to move fluids, such as gases, liquids or slurries. A pump displaces a
volume by physical or mechanical action. One common misconception about pumps is the
thought that they create pressure. Pumps alone do not create pressure; they only displace fluid,
causing a flow. Adding resistance to flow causes pressure. Pumps fall into two major groups:
positive displacement pumps and rotodynamic pumps. Their names describe the method for
moving a fluid.
POSITIVE DISPLACEMENT PUMP
A positive displacement pump causes a fluid to move by trapping a fixed amount of it then
forcing (displacing) that trapped volume into the discharge pipe. A positive displacement pump
can be further classified according to the mechanism used to move the fluid.
Rotary-type, for example, the lobe, external gear, internal gear, screw, shuttle block, flexible
vane or sliding vane, helical twisted roots or liquid ring vacuum pumps.
Reciprocating-type, for example, piston or diaphragm pumps.
GEAR PUMP
This uses two meshed gears rotating in a closely fitted casing. Fluid is pumped around the outer
periphery by being trapped in the tooth spaces. It does not travel back on the meshed part,
since the teeth mesh closely in the centre. Widely used on car engine oil pumps.
22

23. PARISTALTIC PUMP
A peristaltic pump is a type of positive displacement pump used for pumping a variety of fluids.
The fluid is contained within a flexible tube fitted inside a circular pump casing (though linear
peristaltic pumps have been made). A rotor with a number of "rollers", "shoes" or "wipers"
attached to the external circumference compresses the flexible tube. As the rotor turns, the
part of tube under compression closes (or "occludes") thus forcing the fluid to be pumped to
move through the tube. Additionally, as the tube opens to its natural state after the passing of
the cam ("restitution") fluid flow is induced to the pump.
ROTARY PERISTALTIC PUMP
CENTRIFUGAL PUMP
A centrifugal pump is a rotodynamic pump that uses a rotating impeller to increase the
pressure and flowrate of a fluid. Centrifugal pumps are the most common type of pump used to
move liquids through a piping system. The fluid enters the pump impeller along or near to the
rotating axis and is accelerated by the impeller, flowing radially outward or axially into a
diffuser or volute chamber, from where it exits into the downstream piping system. Centrifugal
pumps are typically used for large discharge through smaller heads.
Centrifugal pumps are most often associated with the radial flow type. However, the term
"centrifugal pump" can be used to describe all impeller type rotodynamic pumps[1]
including the
radial, axial and mixed flow variations.
23

24. AXIAL FLOW PUMP
Axial flow pumps differ from radial flow in that the fluid enters and exits along the same
direction parallel to the rotating shaft. The fluid is not accelerated but instead "lifted" by the
action of the impeller. They may be likened to a propeller spinning in a length of tube. Axial
flow pumps operate at much lower pressures and higher flow rates than radial flow pumps.
MIXED FLOW PUMP
Mixed flow pumps, as the name suggests, function as a compromise between radial and axial
flow pumps, the fluid experiences both radial acceleration and lift and exits the impeller
somewhere between 0-90 degrees from the axial direction. As a consequence mixed flow
pumps operate at higher pressures than axial flow pumps while delivering higher discharges
than radial flow pumps. The exit angle of the flow dictates the pressure head-discharge
characteristic in relation to radial and mixed flow.
Compressor
A gas compressor is a mechanical device that increases the pressure of a gas by reducing its
volume.
Compressors are similar to pumps: both increase the pressure on a fluid and both can transport
the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of
a gas. Liquids are relatively incompressible, so the main action of a pump is to pressurize and
transport liquids.
Types of compressors
The main types of gas compressors are illustrated and discussed below:
24

25. Centrifugal compressors
Centrifugal compressors use a rotating disk or impeller in a shaped housing to force the gas to
the rim of the impeller, increasing the velocity of the gas. A diffuser (divergent duct) section
converts the velocity energy to pressure energy. They are primarily used for continuous,
stationary service in industries such as oil refineries, chemical and petrochemical plants and
natural gas processing plants
Many large snowmaking operations (like ski resorts) use this type of compressor. They are also
used in internal combustion engines as superchargers and turbochargers. Centrifugal
compressors are used in small gas turbine engines or as the final compression stage of medium
sized gas turbines
25

26. Diagonal or mixed-flow compressors
Diagonal or mixed-flow compressors are similar to centrifugal compressors, but have a radial
and axial velocity component at the exit from the rotor. The diffuser is often used to turn
diagonal flow .
Axial-flow compressors
Axial-flow compressors are dynamic rotating compressors that use arrays of fan-like airfoils to
progressively compress the working fluid. They are used where there is a requirement for a
high flow rate or a compact design.
The arrays of airfoils are set in rows, usually as pairs: one rotating and one stationary. The
rotating airfoils, also known as blades or rotors, accelerate the fluid. The stationary airfoils, also
known as stators or vanes, decelerate and redirect the flow direction of the fluid, preparing it
for the rotor blades of the next stage.[1]
Axial compressors are almost always multi-staged, with
the cross-sectional area of the gas passage diminishing along the compressor to maintain an
optimum axial Mach number. Beyond about 5 stages or a 4:1 design pressure ratio, variable
geometry is normally used to improve operation.
Reciprocating compressors
Reciprocating compressors use pistons driven by a crankshaft. They can be either stationary or
portable, can be single or multi-staged, and can be driven by electric motors or internal
combustion engines. Small reciprocating compressors from 5 to 30 horsepower (hp) are
commonly seen in automotive applications and are typically for intermittent duty. Larger
reciprocating compressors well over 1,000 hp (750 kW) are commonly found in large industrial
and petroleum applications. Discharge pressures can range from low pressure to very high
pressure (>18000 psi or 180 MPa). In certain applications, such as air compression, multi-stage
double-acting compressors are said to be the most efficient compressors available, and are
typically larger, and more costly than comparable rotary units
26

27. Furnace
A furnace is a device used for heating. The name derives from Latin fornax, oven. The earliest
furnace was excavated at Balakot, a site of the Indus Valley Civilization, dating back to its
mature phase (c. 2500-1900 BC). The furnace was most likely used for the manufacturing of
ceramic
Industrial process furnaces
An industrial furnace or direct fired heater, is an equipment used to provide heat for a process
or can serve as reactor which provides heats of reaction. Furnace designs vary as to its function,
heating duty, type of fuel and method of introducing combustion air. However, most process
furnaces have some common features.
Fuel flows into the burner and is burnt with air provided from an air blower. There can be more
than one burner in a particular furnace which can be arranged in cells which heat a particular
set of tubes. Burners can also be floor mounted, wall mounted or roof mounted depending on
design. The flames heat up the tubes, which in turn heat the fluid inside in the first part of the
furnace known as the radiant section or firebox. In this chamber where combustion takes place,
the heat is transferred mainly by radiation to tubes around the fire in the chamber. The heating
fluid passes through the tubes and is thus heated to the desired temperature. The gases from
the combustion are known as flue gas. After the flue gas leaves the firebox, most furnace
designs include a convection section where more heat is recovered before venting to the
atmosphere through the flue gas stack. (HTF=Heat Transfer Fluid. Industries commonly use
their furnaces to heat a secondary fluid with special additives like anti-rust and high heat
transfer efficiency. This heated fluid is then circulated round the whole plant to heat
exchangers to be used wherever heat is needed instead of directly heating the product line as
the product or material may be volatile or prone to cracking at the furnace temperature.)
27

28. Radiant section
Middle of radiant section
The radiant section is where the tubes receive almost all its heat by radiation from the flame. In
a vertical, cylindrical furnace, the tubes are vertical. Tubes can be vertical or horizontal, placed
along the refractory wall, in the middle, etc., or arranged in cells. Studs are used to hold the
insulation together and on the wall of the furnace. They are placed about 1 ft (300 mm) apart in
this picture of the inside of a furnace. The tubes, shown below, which are reddish brown from
corrosion, are carbon steel tubes and run the height of the radiant section. The tubes are a
distance away from the insulation so radiation can be reflected to the back of the tubes to
maintain a uniform tube wall temperature. Tube guides at the top, middle and bottom hold the
tubes in place.
Convection section
Convection section
28

29. The convection section is located above the radiant section where it is cooler to recover
additional heat. Heat transfer takes place by convection here, and the tubes are finned to
increase heat transfer. The first two tube rows in the bottom of the convection section and at
the top of the radiant section is an area of bare tubes (without fins) and are known as the shield
section, so named because they are still exposed to plenty of radiation from the firebox and
they also act to shield the convection section tubes, which are normally of less resistant
material from the high temperatures in the firebox. The area of the radiant section just before
flue gas enters the shield section and into the convection section called the bridgezone.
Crossover is the term used to describe the tube that connects from the convection section
outlet to the radiant section inlet. The crossover piping is normally located outside so that the
temperature can be monitored and the efficiency of the convection section can be calculated.
The sightglass at the top allows personnel to see the flame shape and pattern from above and
visually inspect if flame impingement is occurring. Flame impingement happens when the flame
touches the tubes and causes small isolated spots of very high temperature.
Burner
The burner in the vertical, cylindrical furnace as above, is located in the floor and fires upward.
Some furnaces have side fired burners, such as in train locomotives. The burner tile is made of
high temperature refractory and is where the flame is contained in. Air registers located below
the burner and at the outlet of the air blower are devices with movable flaps or vanes that
control the shape and pattern of the flame, whether it spreads out or even swirls around.
Flames should not spread out too much, as this will cause flame impingement. Air registers can
be classified as primary, secondary and if applicable, tertiary, depending on when their air is
introduced. The primary air register supplies primary air, which is the first to be introduced in
the burner. Secondary air is added to supplement primary air. Burners may include a premixer
to mix the air and fuel for better combustion before introducing into the burner. Some burners
even use steam as premix to preheat the air and create better mixing of the fuel and heated air.
29

30. The floor of the furnace is mostly made of a different material from that of the wall, typically
hard castable refractory to allow technicians to walk on its floor during maintenance.
Sootblower
Sootblowers are found in the convection section. As this section is above the radiant section
and air movement is slower because of the fins, soot tends to accumulate here. Sootblowing is
normally done when the efficiency of the convection section is decreased. This can be
calculated by looking at the temperature change from the crossover piping and at the
convection section exit. Sootblowers utilize flowing media such as water, air or steam to
remove deposits from the tubes. This is typically done during maintenance with the air blower
turned on. There are several different types of sootblowers used..
Stack
Stack damper
The flue gas stack is a cylindrical structure at the top of all the heat transfer chambers. The
breeching directly below it collects the flue gas and brings it up high into the atmosphere where
it will not endanger personnel.
30

31. The stack damper contained within works like a butterfly valve and regulates draft (pressure
difference between air intake and air exit)in the furnace, which is what pulls the flue gas
through the convection section. The stack damper also regulates the heat lost through the
stack. As the damper closes, the amount of heat escaping the furnace through the stack
decreases, but the pressure or draft in the furnace increases which poses risks to those working
around it if there are air leakages in the furnace, the flames can then escape out of the firebox
or even explode if the pressure is too great.
Insulation
Insulation is an important part of the furnace because it prevents excessive heat loss.
Refractory materials such as firebrick, castable refractories and ceramic fibre, are used for
insulation. The floor of the furnace are normally castable type refractories while those on the
walls are nailed or glued in place. Ceramic fibre is commonly used for the roof and wall of the
furnace and is graded by its density and then its maximum temperature rating. For eg: 8#
2,300°F means 8 lb/ft3
density with a maximum temperature rating of 2,300°F. An example of a
castable composition is kastolite.
31

32. Valves
A valve is a device that regulates the flow of a fluid (gases, liquids, fluidized solids, or slurries)
by opening, closing, or partially obstructing various passageways. Valves are technically pipe
fittings, but are usually discussed as a separate category. In an open valve, fluid flows in a
direction from higher pressure to lower pressure.
Types
Valves are quite diverse and may be classified into a number of basic types. Valves may also be
classified by how they are actuated:
• Hydraulic
• Pneumatic
• Manual
• Solenoid
• Motor
Basic types
Valves can be categorized into the following basic types:
• Ball valve, for on/off control without pressure drop, and ideal for quick shut-off since a
90º turn offers complete shut-off angle, compared to multiple turns required on most
manual valves.
• Butterfly valve, for flow regulation in large pipe diameters.
32

33. • Choke valve, a valve that raises or lowers a solid cylinder which is placed around or
inside another cylinder which has holes or slots. Used for high pressure drops found in
oil and gas wellheads.
• Check valve or non-return valve, allows the fluid to pass in one direction only
• Diaphragm valve, some are sanitary predominantly used in the pharmaceutical and
foodstuff industry.
• Ceramic Disc valve, used mainly in high duty cycle applications or on abrasive fluids.
Ceramic disc can also provide Class IV seat leakage
• Gate valve, mainly for on/off control, with low pressure drop.
Stainless steel gate valve
• Globe valve, good for regulating flow.
• Knife valve, for slurries or powders on/off control.
• Needle valve for accurate flow control.
• Piston valve, for regulating fluids that carry solids in suspension.
• Pinch valve, for slurry flow regulation.
• Plug valve, slim valve for on/off control but with some pressure drop.
• Spool valve, for hydraulic control
• Thermal expansion valve, used in refrigeration and air conditioning systems.
33

34. COOLING TOWERS
A cooling tower is a heat rejection device, which extracts waste heat to the atmosphere though
the cooling of a water stream to a lower temperature. The type of heat rejection in a cooling
tower is termed "evaporative" in that it allows a small portion of the water being cooled to
evaporate into a moving air stream to provide significant cooling to the rest of that water
stream. The heat from the water stream transferred to the air stream raises the air's
temperature and its relative humidity to 100%, and this air is discharged to the atmosphere.
Evaporative heat rejection devices such as cooling towers are commonly used to provide
significantly lower water temperatures than achievable with "air cooled" or "dry" heat rejection
devices, like the radiator in a car, thereby achieving more cost-effective and energy efficient
operation of systems in need of cooling. Think of the times you've seen something hot be
rapidly cooled by putting water on it, which evaporates, cooling rapidly, such as an overheated
car radiator. The cooling potential of a wet surface is much better than a dry one.
Heat transfer method
With respect to the heat transfer mechanism employed, the main types are:
• Wet cooling towers or simply cooling towers operate on the principle of evaporation.
The working fluid and the evaporated fluid (usually H2O) are one and the same.
• Dry coolers operate by heat transfer through a surface that separates the working fluid
from ambient air, such as in a heat exchanger, utilizing convective heat transfer. They do
not use evaporation.
• Fluid coolers are hybrids that pass the working fluid through a tube bundle, upon which
clean water is sprayed and a fan-induced draft applied. The resulting heat transfer
performance is much closer to that of a wet cooling tower, with the advantage provided
by a dry cooler of protecting the working fluid from environmental exposure
•
34

35. Types of Cooling Towers
There are 2 types of towers - mechanical draft and natural draft
Mechanical Draft Towers
Mechanical draft Cooling
Towers have long piping runs
that spray the water downward.
Large fans pull air across the
dropping water to remove the
heat. As the water drops
downward onto the "fill" or
slats in the cooling tower, the
drops break up into a finer
spray. On colder days, tall
plumes of condensation can be
seen. On warmer days, only
small condensation plumes will
be seen.
Natural Draft Towers
35

36. This photo shows a single natural draft
cooling tower as used at a European plant.
Natural draft towers are typically about 400 ft
(120 m) high, depending on the differential
pressure between the cold outside air and the
hot humid air on the inside of the tower as
the driving force. No fans are used.
Whether the natural or mechanical draft
towers are used depends on climatic and
operating requirement condition
Categorization by air-to-water flow
Crossflow
Crossflow is a design in which the air flow is directed perpendicular to the water flow (see
diagram below). Air flow enters one or more vertical faces of the cooling tower to meet
the fill material. Water flows (perpendicular to the air) through the fill by gravity. The air
continues through the fill and thus past the water flow into an open plenum area. A
distribution or hot water basin consisting of a deep pan with holes or nozzles in the
bottom is utilized in a crossflow tower. Gravity distributes the water through the nozzles
uniformly across the fill material.
36

37. Counterflow
In a counterflow design the air flow is directly opposite to the water flow (see diagram below).
Air flow first enters an open area beneath the fill media and is then drawn up vertically. The
water is sprayed through pressurized nozzles and flows downward through the fill, opposite to
the air flow.
Common to both designs:
• The interaction of the air and water flow allow a partial equalization and evaporation of
water.
• The air, now saturated with water vapor, is discharged from the cooling tower.
• A collection or cold water basin is used to contain the water after its interaction with the
air flow.
Both crossflow and counterflow designs can be used in natural draft and mechanical draft
cooling towers.
37

38. Some commonly used terms in the cooling tower industry
• Drift - Water droplets that are carried out of the cooling tower with the exhaust air.
Drift droplets have the same concentration of impurities as the water entering the
tower. The drift rate is typically reduced by employing baffle-like devices, called drift
eliminators, through which the air must travel after leaving the fill and spray zones of
the tower.
• Blow-out - Water droplets blown out of the cooling tower by wind, generally at the air
inlet openings. Water may also be lost, in the absence of wind, through splashing or
misting. Devices such as wind screens, louvers, splash deflectors and water diverters are
used to limit these losses.
• Plume - The stream of saturated exhaust air leaving the cooling tower. The plume is
visible when water vapor it contains condenses in contact with cooler ambient air, like
the saturated air in one's breath fogs on a cold day. Under certain conditions, a cooling
tower plume may present fogging or icing hazards to its surroundings. Note that the
water evaporated in the cooling process is "pure" water.
• Blow-down - The portion of the circulating water flow that is removed in order to
maintain the amount of dissolved solids and other impurities at an acceptable level. It
may be noted that higher TDS (total dissolved solids) concentration in solution results in
greater potential cooling tower efficiency. However the higher the TDS concentration,
the greater the risk of scale, biological growth and corrosion.
• Leaching - The loss of wood preservative chemicals by the washing action of the water
flowing through a wood structure cooling tower.
• Noise - Sound energy emitted by a cooling tower and heard (recorded) at a given
distance and direction. The sound is generated by the impact of falling water, by the
movement of air by fans, the fan blades moving in the structure, and the motors,
gearboxes or drive belts.
• Approach - The approach is the difference in temperature between the cooled-water
temperature and the entering-air wet bulb temperature (twb). Since the cooling towers
are based on the principles of evaporative cooling, the maximum cooling tower
efficiency depends on the wet bulb temperature of the air.
• Range - The range is the temperature difference between the water inlet and water exit.
Heat Exchangers
38

39. “ Heat exchangers are devices built for efficient heat transfer from one fluid to
another and are widely used in engineering processes ”
HEAT EXCHANGERS FUNCTIONS
 Heating / Cooling / Evaporation
 Cooling of lubricants
 Heating of boiler feed water
 Condensing steam for re-use
 Preheating
Types of heat exchangers
Shell and tube heat exchanger
Shell and tube heat exchangers consist of a series of tubes. One set of these tubes contains the
fluid that must be either heated or cooled. The second fluid runs over the tubes that are being
heated or cooled so that it can either provide the heat or absorb the heat required. A set of
tubes is called the tube bundle and can be made up of several types of tubes: plain,
longitudinally finned, etc. Shell and Tube heat exchangers are typically used for high pressure
applications (with pressures greater than 30 bar and temperatures greater than 260°C).[2]
This is
because the shell and tube heat exchangers are robust due to their shape.
39

40. Plate heat exchanger
Another type of heat exchanger is the plate heat exchanger. One is composed of multiple, thin,
slightly-separated plates that have very large surface areas and fluid flow passages for heat
transfer. This stacked-plate arrangement can be more effective, in a given space, than the shell
and tube heat exchanger.
40

41. Adiabatic wheel heat exchanger
A fourth type of heat exchanger uses an intermediate fluid or solid store to hold heat, which is
then moved to the other side of the heat exchanger to be released. Two examples of this are
adiabatic wheels, which consist of a large wheel with fine threads rotating through the hot and
cold fluids, and fluid heat exchangers.
Plate fin heat exchanger
This type of heat exchanger uses "sandwiched" passages containing fins to increase the
effectivity of the unit. The designs include crossflow and counterflow coupled with various fin
configurations such as straight fins, offset fins and wavy fins.
Plate and fin heat exchangers are usually made of aluminium alloys which provide higher heat
transfer efficiency. The material enables the system to operate at a lower temperature and
reduce the weight of the equipment. Plate and fin heat exchangers are mostly used for low
temperature services such as natural gas, helium and oxygen liquefaction plants, air separation
plants and transport industries such as motor and aircraft engines.
Advantages of plate and fin heat exchangers:
• High heat transfer efficiency especially in gas treatment
• Larger heat transfer area
• Approximately 5 times lighter in weight than that of shell and tube heat exchanger
• Able to withstand high pressure
Disadvantages of plate and fin heat exchangers:
• Might cause clogging as the pathways are very narrow
• Difficult to clean the pathways
41

42. Fluid heat exchangers
This is a heat exchanger with a gas passing upwards through a shower of fluid (often water),
and the fluid is then taken elsewhere before being cooled. This is commonly used for cooling
gases whilst also removing certain impurities, thus solving two problems at once. It is widely
used in espresso machines as an energy-saving method of cooling super-heated water to be
used in the extraction of espresso.
Phase-change heat exchangers
In addition to heating up or cooling down fluids in just a single phase, heat exchangers can be
used either to heat a liquid to evaporate (or boil) it or used as condensers to cool a vapor and
condense it to a liquid. In chemical plants and refineries, reboilers used to heat incoming feed
for distillation towers are often heat exchangers
42

43. FUEL REFINERY
S.No Units
1. Crude distillation unit
2. Naphtha Hydrobon unit
3. Platforming unit
4. Kero Hydrobon unit
5. L.P.G Naphtha and Kerosene Sweetening Units
6. Propane Recovery Unit
7. B.T.X Unit
CRUDE DISTILLATION UNIT
43

44. In all refineries, crude distillation is the starting point of the refining operations. The overhead
product of distillation column is Straight Run Naphtha. This is passed through a stabilizer
column to recover LPG. The stabilized Naphtha enters into a splitter column, Light Naphtha is
obtained from the top and Heavy Naphtha from the bottom of the splitter column. Light
Naphtha is used for Gasoline blending whereas major part of Heavy Naphtha is upgraded at Plat
forming unit. Naphtha is also exported as feedstock for petrochemical plants.
This Crude Distillation Unit has been revamped for capacity enhancement by about 45% in
which a pre-flash unit was added and the heat exchanger scheme was optimized. This way the
capacity enhancement was made possible without additional fuel oil consumption.
After the revamp ;the pre-heated crude feed is now pre-flashed in a column to recover
maximum of its Naphtha. The pre-flashed crude then follows the conventional flow scheme as
narrated above.
NAPHTHA HYDRO ON UNIT
This unit is designed to hydro treat the Heavy Naphtha fraction produced in Crude Distillation
Units of the Lube and Fuel refineries. Sulphur and Nitrogen are poisons for reforming catalyst
hence removed by Hydro treating Naphtha.
This is a high severity process operated in the presence of a catalyst and hydrogen.
PLATFORMING UNIT
The term “Platforming” is applied to catalytic reforming process where chemical conversion of
the hydrocarbon feed is achieved on a bed of platinum based catalyst under extreme conditions
of pressure and temperature. Hydrotreated Naphtha is the feed to this unit which is converted
into high Octane Motor Gasoline.
44

45. As part of the Balancing & Modernization Project, the Platforming Unit has also been revamped
for capacity enhancement by 72% of design. Adoption of Radial Flow Reactors and new
improved catalyst has further enhanced the performance and operating cycle of the unit.
KERO HYDROBON UNIT
Essentially similar to the Naphtha hydrotreating process; this unit further refines Sour Kerosene
feedstock into the commercial Aviation Turbine Fuel, JP-1 by catalytic hydro treating. The fuel
used in the Military Air Crafts JP-4 is also produced at Fuel Refinery by blending JP-1 and
Naphtha. Currently not in operation.
FUEL PRODUCTS
 Motor Gasoline (MOGAS)
 Kerosene (SKO)
 JP1
 P4
 High Speed diesel Oil (HSD)
 Light diesel oil (LDO)
 Furnace Oil (F.O)
 Liquefied Petroleum Gas (LPG)
 Naphtha
45

46. LUBE REFINERY
S.No Units
1. Atmospheric and Vaccum Distillation Unit
2. Propane Deasphalting Unit
3. Furfural Extraction Unit
4. M.E.K Dewaxing Unit
5. Hydro finishing Unit
6. Asphalt Air Blowing Unit
46

47. LUBE-I REFINERY
The primary process unit of the Lube-I Refinery is distillation of electrically Desalted Crude Oil in
two stages. In the first stage, the atmospheric distillation; the relatively light fuel components,
Gases, Naphtha, Kerosene and Light Diesel Oil are separated from the parent Crude Oil. The
remaining reduced crude (Furnace Oil) is then processed under vacuum in the second
distillation stage to produce Gas Oil (Diesel), Lubricating Oil Distillates and Vacuum Residue.
Vaccum Diatillation
Process Description:
For the ease of operating condition and control, the unit is divided into the
following sections:
1. Reduced Crude Preheat And Vacuum Heater Section
2. Vacuum Distillation Section
1.Reduced Crude Preheat And Vacuum Heater Section
Reduced crude is brought in the VACUUM DISTILLATION UNIT via suction line from the unit feed
tanks OSBL. Feed pump discharge the material through charge preheat exchanger train, where
heat is picked up in each successive exchangers. Preheat exchanger train consist of seven
different heat exchangers. Reduced Crude enters the first preheat exchanger at about 1100
C
and leaves the last preheat exchanger at 3000
C. The preheated feed then goes to the VACUUM
HEATER, which raises Reduced Crude temperature from 3000
C to 3950
C. The charge is fed to the
heater through four coils. The preheated Reduced Crude enters first in the CONVECTIVE
SECTION of the VACUUM HEATER and after absorbing heat Reduced Crude enters the RADIANT
SECTION in four different parts, where it attains the desired temperature. SHS steam is injection
in each coil, at the rate of 1756.5 kg/hr at 3700
C.
47

48. 2.Vacuum Distillation Section:
Partially Flashed Reduced Crude leaves the VACUUM HEATER and enters in the FLASH ZONE of
VACUUM TOWER.
TOWER DETAIL:
It consists of 33 trays.
It has 3 chimney trays.
It has 2 demister pads.
Operated at a pressure of about 94 Kpa..
The overall temperature gradient is controlled by the following three REFLUXES:
1. Top Pump Around
2. Middle Pump Around
3. Bottom Pump Around
TOP PUMP AROUND:
This reflux controls the Vacuum Tower top temperature. It is drawn from the TOP CHIMNEY
TRAY which is fitted between TRAY NO 1 & TRAY NO 2. Hot LVGO is returned to VACUUM
TOWER at TRAY NO 3 without cooling as TOP REFLUX. Rest of the stream is cooled in AIR
COOLER. The stream is again splitted, part is sent to the 1st TRAY as TOP PUMP AROUND.
Balance of this stream is cooled in HEAT EXCHANGER and sent to the storage tank.
MIDDLE PUMP AROUND:
The purpose of this pump around is to provide liquid for cooling down the up going vapors from
the middle section of Vacuum Tower. It is drawn from TRAY NO. 9, cooled in different
exchangers and finally returned to TRAY NO. 6 of VACUUM TOWER.
BOTTOM PUMP AROUND:
The purpose of this pump around is to provide liquid for cooling the vapors going towards the
FRACTIONATION section of the tower. It is drawn from TRAY NO. 21 passed through different
exchangers and finally returned to TRAY NO. 18 of VACUUM TOWER
48

49. Vaccum steam
The steam and overhead vapors leaving the tower enter the vacuum overhead precondenser
where condensation occurs. The vacuum is maintained with the help of STEAM EJECTORS.
Vapors pass through the shell side and are condensed by circuating cooling water in tube of the
condensers. MP steam is supplied to ejectors. Normally one set of ejectors is kept in service.
Liquid hydrocarbon and condensate from condensers are collected in overhead condensate
receiver. The steam condensate and liquid hydrocarbon is separated in condensate receiver.
The sour water flows by gravity to the sewer and hydrocarbon which separates out is pumped
to slop tank.
PROPANE DEASPHALTING UNITS
INTRODUCTION:
The Propane Deasphalting is a process for producing high viscosity deasphalting oil from the
bottom of Vacuum Distillation tower. This is achieved by liquid-liquid extraction of Vacuum
Bottom (Residue) and Propane in a extractor under controlled conditions of temperature &
pressure.
The removal of ASPHALTENES and RESINS is accomplished in Propane De-Asphalting unit before
undergoing solvent extraction processes.
Primary objective of Propane De-Asphalting unit is to prepare Bright Feed stocks to other to
Refining and Finishing units i.e. Furfural Extraction unit and Methyl Ethyl Ketone units).
FEED TO PROPANE DE-ASPHALTING UNIT:
Feed to Propane De-asphalting unit may be either the bottom stream of Atmospheric
Distillation tower or the Vacuum Distillation tower. Some times the highest boiling distillate
stream may also contain sufficient asphaltenes and resins to justify DE-ASPHATING.
PROPANE DE-ASPHALTING produce two products:
DAO i.e. De-Asphalted Oil (Bright stock)
RESID or Propane De-Asphalted Tar
49

50. PROCESS DESCRIPTION:
In Propane Deasphalting unit, Vacuum Residue is contacted counter currently with liquid
Propane in the Extractor which gives overhead fraction of Deasphalted oil mixed with propane
and bottom fraction of Asphalt mixed with propane.
Propane is recovered from both streams in DAO & Resid recovery sections and is then
recycled to the Extractor.
The Propane Deasphalting Unit is divided into following section
1. Feed and Extraction Section
Feed temperature at unit feed tank is approximately 110°
C. Since Vacuum bottom is
very thick and viscous so positive displacement screw pumps are used to handle the
feed. The feed temperature is lowered by passing through shell side of Heat Exchangers.
The feed is fed to the Extractor at two different points.
2. Deasphalted Oil Recovery Section
Propane from DAO mix is recovered by triple effect evaporation, which is achieved in
low pressure, medium pressure and high pressure flash towers. Remaining propane is
stripped out in DAO stripper with stripping steam.
3. Resid Recovery Section
Propane from the Resid-mix is recovered by single stage flash distillation followed by
steam stripping. The bottom stream from the extractor is 50:50 mixture of propane and
Resid. The Pressure in the flash vessel is about 18.0 bar. The residmix from the bottom
of flash tower flows to the stripper The stripper has ten shower trays. Superheated
steam is injected to strip out the propane. The resid product is made rundown after
heat exchanging in heat exchangers to the respective tanks
4. Propane Distribution & Recovery Section
Propane vapors from DAO LP flash tower passes through fin fan condenser where is
partially condensed and are then joined with the overhead vapors of Redid flash vessel
and then passed through propane condenser. Condensed propane then goes to
propane vessel at about 52o
C
50

51. FURFURAL EXTRACTION UNITS
Lubricating oils distillates from Two-Stage Unit and from Propane Deasphalting Unit are
processed here turn by turn, for extraction of undesirable hydrocarbons with furfural solvent.
This improves the colour of the oils and enhances their ability to maintain their lubricating
properties under varying temperature conditions. Nine intermediate lube base oils are
produced at this unit, which are called Raffinates. The ‘undesirables’ for lubes called Extracts
are sent to the refinery asphalt production unit or sold as Speciality Oil.
The Furfural Extraction Unit installed in second Lube Refinery, employs advanced techniques
ensuring better solvent recovery and energy conservation.
M.E.K. DEWAXING UNITS
INTRODUCTION:
The solvent dewaxing process involves the removal of naturally occurring waxes from
petroleum fractions by means of suitable solvents at low temperatures. It has been found
that the solubility characteristics of single solvent with respect to both oil and wax are not
suited for dewaxing purposes as blends of two SOLVENTS
The MEK Dewaxing process employs a mixed solvent consisting of an oil solvent, Toluene,
which ensures complete solubility of the oil at the filtering temperature without excessive
solvent action upon the wax, and a wax anti solvent, MEK, which ensures precipitation of
the wax necessary to obtain the desirable pour point of the oil.
FEED TO MEK DEWAXING UNIT:
The MEK Dewaxing unit is designed to dewax in blocked operation, various grades of
Furfural extraction unit Raffinates derived from Arabian Light Vacuum distillate and
Deasphalted oil
PROCESS
In this unit, the wax content in Raffinates coming from Furfural Extraction Units is removed by
process of extraction with a mixture of Methyl Ethyl Ketone (MEK) & Toluene solvent mixture.
Subsequent filtration at very low temperature is achieved by a process of Propane refrigeration.
51

52. All the nine lube intermediates from the Furfural Extraction Unit are subjected, in blocked-out
operation to this dewaxing process. This process improves pour point or cold flow properties of
lubricating oil. The wax separated in the process is also marketed as a product called Slack Wax.
At M..E.K. Dewaxing Unit of Lube-II Refinery, the process has been improved which has resulted
in higher yields and has considerably reduced solvent losses. Provisions have also been made in
the process for the maximum heat recovery thereby improving the efficiency.
HYDROFINISHING UNIT
In this final processing stage, the lube base oils are stabilized and their colour is further
improved by hydrogenation under severe operating conditions in the presence of a catalyst.
The hydrofinished lube oils are dispatched to refinery storage tanks for distribution to Oil
Marketing/Lube Oil Blending Companies.
ASPHALT AIR BLOWING UNIT
The residual effluents from the two Propane De-Asphalting and Furfural Extraction Units are
blended and oxidized with air for the production of paving and industrial grade asphalts.
52

53. LUBE-II REFINERY
The construction work of 2nd lube refinery was started in 1983 the refinery came into
production in 1985 with production capacity of 100,000 M tons/annum of various grades of
Lube base oil and 100,000 M tons of asphalt per annum. Refinery was designed by TEXACO and
was installed by EI(Industrial Export Import) ROMANIA with a project cost of 1416 million Rs.
originally Lube-II Refinery was designed on Replup mode but since long Arabian light crude is
being processed due to more suitability for making lube base oil.
The second Lube Refinery starts with a vacuum distillation unit. The feedstock (Reduced Crude)
obtained from Fuel Refinery is converted into High Speed Diesel Oil, Light Diesel Oil, Lubricating
Oil Distillates and Vacuum Residue.
LUBE BASE OILS PRODUCTS
• HVI GRADES
• 65N - HVI
• 100N - HVI
• 150N - HVI
• 400N - HVI
• 500N - HVI
• BS – HVI
• MVI GRADES
• 100N - MVI
• 650N – MVI
• BS - MVI
• OUR SPECIALITY PRODUCTS INCLUDE :
• BENZOL
• TOLUOL
• XYLOL
• SLACK WAX
• LOW MELT
• MEDIUM MELT
• JBO
• RPO
53

54. UTILITIES
National Refinery utilizes a large Number of utilities to support the manufacturing at production
units. The supply of water, steam, fuel and air is the assignment of Utilities Department. A
comprehensive utilities complex exists to meet the refinery’s requirements of utilities, steam,
condensate, cooling water, instrument/plant air and fuels. This consists of three Demin / Water
Treatment plants, three condensate recovery plants, five high pressure steam boilers, four
induced draft cooling towers, a number of instrumentation/plant air compressors and two units
for refinery fuel gas and fuel oil system.
POWER GENERATION
Recently, National Refinery has completed its project of Self-Power Generation. Self-Power
Generation plant has a 7.5 MW steam turbo-generator and a 4.0 MW Diesel-Fuel Oil Engine
Power Generator.
The self-power generation is meant for continuous uninterrupted power supply and to avoid
plant shut-down and production loss due to power break- down.
OIL MOVEMENT AND SHIPPING
Huge quantity and variety of crude oils, about 3 million ton per annum and about equal
tonnage distributed in about thirty products are handled at NRL. For this, elaborate system of
pumping stations, pipelines, tankage and loading gantries are maintained. The inventory of
crude oil and products stored at refinery tankage has enormous monetary value. This operation
involves receipt and transfer of crude oil from port terminal, inland domestic crude oil receipts,
transfer to and receipts from processing units, product transfer to Oil Marketing Companies,
product shipment through tank lorry filling gantries.
A whole maze of pipelines and over one hundred and fifty crude oil and product storage tanks
are utilized for this purpose. Shipping Department works side-by-side with Oil Movement to
facilitate documentations and coordination with Excise Authorities.
54

55. QUALITY CONTROL
All raw material entering NRL are tested to ensure that they meet contractual specifications.
At Input stage testing is performed on
• Crude Oil (Imported / Local)
• Condensates
• Additives
• Chemicals
Test Methods
• ASTM Test Methods
• IP Test Methods
• UOP Test Methods
• APHA Test Methods
Important Fuel Test
• Color ASTM D- 156 / 1500
• Specific Gravity ASTM D-1298
• Distillation ASTM D- 86
• Viscosity ASTM D- 445
• RVP ASTM D- 323
• Flash Point IP 170 / D- 93
• Pour Point ASTM D- 97
55

56. • Sulphur ASTM D-4294
• Mercapten ASTM D-3227
• Copper Corrosion ASTM D- 130
• Octane Number ASTM D-2699
• Con Carbon ASTM D- 189
• WSIM ASTM D-3948
• JFTOT ASTM D-3241
Color ASTM D- 156 / 1500
Determination of the color of petroleum products is used mainly for manufacturing control
purposes and is an important quality characteristic since color is readily observed by the user of
the product.
Specific Gravity ASTM D-1298
Accurate determination of the density, relative density (specific gravity), or API gravity of
petroleum and its products is necessary for the conversion of measured volumes to volumes or
masses, or both, at the standard reference temperatures during custody transfer.
Distillation ASTM D – 86
 The distillation (volatility) characteristics of hydrocarbons have an important effect on
their safety and performance, especially in the case of fuels and solvents.
 The boiling range gives information on the composition, the properties, and the
 behavior of the fuel during storage and use
56

57. Viscosity ASTM D - 445
the viscosity of many petroleum fuels is important for the estimation of optimum storage,
handling, and operational conditions
RVP ASTM D- 323
Vapor pressure is critically important for both automotive and aviation gasolines,
affecting starting, warm up, and tendency to vapor lock with high operating
temperatures or high altitudes. Maximum vapor pressure limits for gasoline are legally
mandated in some areas as a measure of air pollution control.
Flash Point IP 170 / 3D- 9
The flash point temperature is one measure of the tendency of the test specimen to form a
flammable mixture with air under controlled laboratory conditions. It is only one of a
number of properties which must be considered in assessing the overall flammability hazard
of a materials.
Viscosity Index (VI) ASTM D - 2270
The viscosity index is a widely used and accepted measure of the variation in kinematic
viscosity due to changes in the temperature of a petroleum product between 40 and 100 o
C.
Important Asphalt test
• Flash Point ASTM D - 92
• Penetration ASTM D - 05
• Softening Point ASTM D - 36
57