CERTIFICATE

This is to certify that Mr. MOHIT SHARMA, a student of SARDAR

VALLABHBHAI NATIONAL INSTITUTE OF TECHNOLOGY, SURAT has
successfully completed his industrial training at INDIAN OIL CORPORATION LTD,
GUJARAT REFINERY, from 13/05/2012 to 12/06/2012 under my supervision and
guidance with utmost satisfaction.

It indeed gives us pleasure to highlight that Mr. ,MOHIT SHARMA has worked
hard and with deep sincerity throughout his vocational training. I appreciate his sincere
efforts and I am sure that the experience gained during the training will enable him to take up
more challenging tasks in the future.

Mr. C. P. AMBEDKER
Dy. Manager (Trg. & Dev.)
IOCL, Vadodara

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Gujrat Refinery

ACKNOWLEDGEMENT
The summer training at Indian Oil Corporation Ltd., Gujarat Refinery was a wonderful
experience. Whatever I learnt during the training has been brought out in the form of this
training report. I, hereby take the opportunity to thank all the people who have imparted their
invaluable knowledge to me.

I bestow my gratitude to Mr. C. P. AMBEDKAR, Dy. Manager (Trg. & Dev.) for
granting me the permission to obtain training at Indian Oil Corporation Ltd, Gujarat
Refinery.

I am thankful to Mr. M.M. Parmar, Chief Production Manager (CPNM), Gujarat

Refinery, my industry mentor, for continuously guiding and encouraging me at each step of
my training. He not only solved my difficulties, but also shared his immense experience of
his service in the industry. This was the most valuable thing I earned at Indian Oil
Corporation Ltd., Gujarat Refinery. My training would have been remained incomplete
without my mentor.

I wish to warmly thank Mr. J.D. Parekh (DMPN) of OM&S, Mr. K.M. Tamboli
(PNM) of GR-1, Mr. P.B. Raval (DMPN) of FCC and Mr. R.K. Pandey (DMPN) of
GHP for their consistent guidance and support in their respective units throughout my
training and for constantly ensuring that the training is opening up new aspects of chemical
industry for my learning.

I am highly indebted to Dr. Z.V.P. MURTHY (Head of Department, Chemical

Engineering, SVNIT) & Dr. D.V. Bhat (Training & Palcement Officer) for deputing me
to Indian Oil Corporation Ltd. for training.

I, finally, would like to thank all the staff and officials of Indian oil Corporation Ltd.,
Gujarat Refinery for all the help they provided during the training.

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CONTENT

IOCL Company Profile

Gujrat Refinery An Overview

Gujrat Hydrocracker Unit

11

Introduction

12

HCU at G.R.

13

HydrocrackingProcess Chemistry

14

Process Description

18

Critical Equipments

21

Product Routing

31

Instrumentation

32

Safety Measures Adopted

35

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INDIAN OIL CORPORATION LIMITED

COMPANY PROFILE

Indian Oil, the largest commercial enterprise of India (by sales turnover), is Indias sole
representative in Fortune's prestigious listing of the world's 500 largest corporations, ranked
189 for the year 2004. It is also the 17th largest petroleum company in the world. Indian Oil
has a sales turnover of ` 1, 20,000 crore and profits of ` 8,000 crore. Indian Oil has been
adjudged second in petroleum trading among the 15 national oil companies in the AsiaPacific region. As the premier National Oil Company, Indian Oils endeavor is to serve the
national economy and the people of India and fulfill its vision of becoming "an integrated,
diversified and transnational energy major."
Beginning in 1959 as Indian Oil Company Ltd, Indian Oil Corporation Ltd. was formed in
1964 with the merger of Indian Refineries Ltd. (Est. 1958). As India's flagship national oil
company, Indian Oil accounts for 56% petroleum products market share, 42% national
refining capacity and 67% downstream pipeline throughput capacity. IOCL touches every
Indians heart by keeping the vital oil supply line operating relentlessly in every nook and
corner of India. It has the backing of over 33% of the countrys refining capacity as on 1st
April 2002 and 6523 km of crude/product pipelines across the length and breadth of the
country. IOCLs vast distribution network of over 20000 sales points ensures that
essential petroleum products reach the customer at the right place and at the right
time
Indian Oil controls 10 of India's 18 refineries - at Digboi, Guwahati, Barauni, Koyali, Haldia,
Mathura, Panipat, Chennai, Narimanam and Bongaigaon - with a current combined
rated capacity of 49.30 million metric tones per annum (MMTPA) or 990 thousand
barrels per day (bpd).
Indian Oils world-class R&D Center has won recognition for its pioneering work in
lubricants formulation, refinery processes, pipeline transportation and bio-fuels. It has
developed over 2,100 formulations of SERVO brand lubricants and greases for virtually all
conceivable applications - automotive, railroad, industrial and marine - meeting stringent
international standards and bearing the stamp of approval of all major original equipment
manufacturers. The center has to its credit over 90 national and international patents. The
wide range of
brand lubricants, greases, coolants and brake fluids meet stringent
international standards and bear the stamp of approval of all major original equipment
manufacturers.
Indian Oil operates 17 training centers throughout India for up-skilling, re-skilling and
multi-skilling of employees in pursuit of corporate excellence. Among these, the foremost
learning centers -- the Indian Oil Institute of Petroleum Management at Gurgaon, the Indian
Oil Management Center for Learning at Mumbai, and the Indian Oil Management Academy
at Haldia -- have emerged as world-class training and management academies. Indian Oil
Institute of Petroleum Management, the Corporation's apex center of learning, conducts
advanced management development programmes in collaboration with reputed institutes. It
also offers a unique mid-career International MBA programme in Petroleum Management.

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Indian Oil aims at maintaining its leadership in the Indian hydrocarbon sector by continuous
assimilation of emerging Information Technology and web-enabled solutions for integrating
and optimizing the Corporation's hydrocarbon value chain. It is currently implementing an
IT re-engineering project titled Manthan, which includes an Enterprise Resource planning
(ERP) package which will standardize and integrate the Corporation's business on a common
IT platform through a robust hybrid wide area network with appropriate hardware.
Refineries
Digboi Refinery, in Upper Assam, is India's oldest refinery and was commissioned in 1901.
Originally a part of Assam Oil Company, it became part of IndianOil in 1981. Its original
refining capacity had been 0.5 MMTPA since 1901. Modernisation project of this refinery
has been completed and the refinery now has an increased capacity of 0.65 MMTPA.
Guwahati Refinery, the first public sector refinery of the country, was built with Romanian
collaboration and was inaugurated by Late Pt. Jawaharlal Nehru, the first Prime Minister of
India, on 1 January 1962.
Barauni Refinery, in Bihar, was built in collaboration with Russia and Romania. It was
commissioned in 1964 with a capacity of 1 MMTPA. Its capacity today is 6 MMTPA.
Gujarat Refinery, at Koyali in Gujarat in Western India, is IndianOils largest refinery. The
refinery was commissioned in 1965. It also houses the first hydrocracking unit of the country.
Its present capacity is 13.70 MMTPA.
Haldia Refinery is the only coastal refinery of the Corporation, situated 136 km downstream
of Kolkata in the Purba Medinipur (East Midnapore) district. It was commissioned in 1975
with a capacity of 2.5 MMTPA, which has since been increased to 5.8 MMTPA
Mathura Refinery was commissioned in 1982 as the sixth refinery in the fold of IndianOil
and with an original capacity of 6.0 MMTPA. Located strategically between the historic
cities of Delhi and Agra, the capacity of Mathura refinery was increased to 7.5 MMTPA.
Panipat Refinery is the seventh refinery of IndianOil. The original refinery with 6 MMTPA
capacity was built and commissioned in 1998. Panipat Refinery has doubled its refining
capacity from 6 MMT/yr to 12 MMTPA with the commissioning of its Expansion Project.
Bongaigaon Refinery is the eight refinery of Indian Oil. It became the eighth refinery of
Indian Oil Corporation Limited after merger of Bongaigaon Refinery & Petrochemicals
Limited with IOCL w.e.f. 25th March 2009. It is located at Dhaligaon in Chirang district of
Assam, 200 Kms west of Guwahati.The present crude processing capacity of the refinery is
2.35 MMTPA. The refinery has two Crude Distillation Units of 1.35 MMTPA and 1.00
MMTPA capacities, two Delayed Coker Units each of 0.5 MMTPA capacity, one Coke
Calcination Unit of 0.075 MMTPA and Catalytic Reformer of 160,000 MTPA naphtha feed
capacity and an LPG Bottling Plant.
Indian Oil controls 10 of India's 18 refineries with a current combined rated capacity of
49.30 million metric tonnes per annum (MMTPA). All refinery units are accredited with
ISO 9002 and ISO 14001 certifications.

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GUJARAT REFINERY
AN OVERVIEW

The Gujarat Refinery at Koyali in Gujarat in Western India is Indian Oils largest
refinery. The refinery was commissioned in 1965. Its facilities include five atmospheric
crude distillation units. The major units include CRU, FCCU and the first
Hydro- cracking unit of the country. Through a product pipeline to Ahmedabad and a
recently commissioned product pipeline connecting to BKPL product pipeline and also by rail
wagons/trucks, the refinery primarily serves the demand for petroleum products in
western and northern India.
When commissioned, the Gujarat refinery had a design capacity of 3.0 MMTPA. The
capacity has since been increased to its present capacity of 13.70 MMTPA by low cost
debottlenecking. The company has already commissioned the facilities for MTBE and
Butene-1 production. The refinery also produces a wide range of specialty products like
Benzene, Toluene, Food Grade Hexane, solvents, LABFS, etc. The Gujarat Refinery
achieved the distinction of becoming the first refinery in the country to have completed the
DHDS (Diesel Hydro De-sulphurisation) project in June 1999, when the refinery started
production of HSD with low sulphur content of 0.25% wt (max.).
A project for production of high value LAB (Linear Alkyl Benzene -- which is one of the
major raw materials used in manufacturing detergents) from kerosene streams has been
completed recently and started on 15th August, 2004. In order to meet future fuel quality
requirements, MS quality improvement facilities are planned to be installed by
2006.
Some of the salient features of Gujarat Refinery are:
1) First Riser Cracker FCCU in the country
2) First Hydro Cracker in the country
3) First Diesel Hydro Desulfurisation Unit in the country
4) First spent caustic treatment plant in refineries
5) First automated rail loading gantry
6) First LPG mounded bullets in Indian refineries
7) State-of-the-art CETP
8) Quality Management System (ISO- 9001:2000)
9) Environmental Management System (ISO 14001)
10) International Safety Rating System (ISRS) LEVEL 9(Highest) First
organization in country; one amongst 30 refineries in world

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UNITS AT GUJARAT REFINERY

1) GR1
Atmospheric Distillation Units, AU1 & AU2
AU5
Catalytic Reforming Unit, CRU

:
:
:

4.2
3.0
0.33

MMTPA
MMTPA
MMTPA

:
:
:
:

2.7
0.166
0.03
47
2

MMTPA
MMTPA
MMTPA
MMTPA
MMTPA

2) GR2
AU3
UDEX
Food Grade Hexane, FGH
Methyl Tertiary Butyl Ether, MTBE
BUTENE 1
Pilot Distillation Fraction, PDF

3) GRE
AU4
Vacuum Distillation Unit, VDU
Bitumen Blowing Unit, BBU
Visbreaker Unit, VBU

:
:
:

3.8 MMTPA
1.2 MMTPA
0.5 MMTPA
1.6 MMTPA

:
:

2.0
1.5

:
:
:
:
:
:

2.97
MMTPA
38,000 MTPY
1.2
MMTPA
10,000 MTPY
1.4
MMTPA
88
MMTPD

4) GRSPF
Feed Preparation Unit, FPU-1
Fluidized Catalytic Cracking Unit, FCCU

MMTPA
MMTPA

5) GHC
FPU-2
Hydrogen Generation Unit, HGU-1
Hydro Cracking Unit, HCU
HYDROGEN-2
Diesel Hydro De-Sulfurization Unit, DHDS
Sulphur Recovery Unit, SRU
Nitrogen Unit

6) POWER GENERATION & EFFLUENT TREATMENT

Cogeneration Plant, CGP
Thermal Power Station, TPS
Combined Effluent Treatment Plant, CETP

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:
:
:

Gujrat Refinery

30*3
MW
12*2 + 12.5 MW
1500 M3/H

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PRODUCT
LPG
Benzene
Toluene
Naphtha
Motor Spirit (90 Octane)
Aviation Turbine Fuel (ATF)
Superior Kerosene (SK)
High Speed Diesel (HSD)
Light Diesel Oil (LDO)
Low Sulphur Heavy Stoke (LSHS)
Fuel Oil (FO)
Bitumen
n-Heptane
ARO
Linear Alkyl Benzene (LAB)
Butene

END USES
Cooking Gas (marketed as INDANE)
Raw material for petrochemicals
Raw material for petrochemicals
Raw material for petrochemicals
Petrol for vehicles
Fuel for jet aircraft
Illuminant, domestic purpose
Diesel locos, trucks, buses, ships
Small engines attached to irrigation pumps
Fuel in thermal power stations
Industrial Furnaces/Boilers
Road surfacing
As solvent
Used in aluminium rolling industries
Detergent Manufacture
Co-polymer for producing polyethylene and
Polypropylene
Blending in gasoline for increasing octane
number and oxygen content
Solvent for oil seed extraction.
Glues/Adhesives
for
foot
wear
Polymerization reactions in industries like
Pharmaceuticals & printing ink. Retreading
of car tyres
Sulphuric acid and tyre manufacture

Methyl Tertiary Butyl Ether (MTBE)

Food Grade Hexane (FGH)

Sulphur

GUJARAT REFINERY (A Mother Industry)

IPCL

NIRMA

LAB, Cracked LPG

Naphtha, FGH

Gujarat Carbon
BUTENE-2

LAB

IFFCO
Naphtha

Chemical Ind.
Toluene

Industrial Training Report |

GSFC
Benzene, Sulfur,
Naphtha

Aluminium Ind.
LARO

IOCL|

Gujrat Refinery

PowerPlants
LSHS

Block diagram for Gujrat Refinery

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GUJRAT
HYDROCRACKER
UNIT

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INTRODUCTION

Hydrocracker Technology
Hydrocracking is an extremely versatile catalytic process in which feed stock ranging from
Naphtha to Vacuum Residue can be processed in presence of Hydrogen and catalyst to
produce almost any desired products lighter than the feed. Thus if the feed is Naphtha, it can
be converted into LPG and if feed is Vacuum Gas Oil as in our Refinery, it can produce LPG,
Naphtha, ATF, Diesel in varying proportions as per design requirement.
Why Hydrocracking ?
Residue upgradation into middle distillates and light distillates is currently being done in the
Indian Refineries primarily by employing FCC process, delayed Coking process &
visbreaking. Visbreaking is adopted primarily to reduce the viscosity of the residue thereby
making it marketable. Delayed coking is adopted if Coke is also to be a product.
The quality of products obtained from FCC, delayed Coker & Visbreaker are relatively poor
in quality with respect to stability, & sulphur and have to be blended with other straight run
products to be able to market them.
In view of these problems Hydrocracking process is gaining more and more popularity for
upgrading residues into higher value products. A comparison of typical operating conditions
adopted in the above processes and the product yields is given in the Table below

a. Feed Stock
b. Operating temp. deg. C
c. Operating pressure kg/cm2
d. Catalyst
e. Hydrogen Environment
f. Product yields % on feed
- Lt. distillates 25
- middle distillates
- Heavy ends+coke

Delayed Coker
RCO
480
5.0
None

FCC
VGO
470
3.0
Si/Al

None
25
22
48

None
35
45
15

Hydrocracker
VGO
400-440
170-175
Si/Al with Metal Sulphides
of (Ni-Co-Fe) (Mo-W-V)
Yes
17
80
Nil

It is seen from the above that Hydrocracking process is best suited for maximising the
production of distillates from a given feedstock.

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HYDROCRACKING IN G.R.

Need For The Hydrocracker At Gujarat Refinery

Gujarat Refinery has been processing the Bombay High crude oil as well as imported crude
oils also in addition to the Gujarat Crude Oils. North Gujarat Crudes are low sulphur but
highly corrosive due to high Naphthenic acid content, yield high amount of residues (about
70%) and are difficult for transportation through pipe lines over long distances due to their
waxy nature. With increased amount of North Gujarat Crude processing in the the production
of heavy residues (LSHS) from Gujarat Refinery increased and posed problems for disposal
due to inadequate market for the same. On the contrary, the demand for middle distillates
(Kerosene & High Speed Diesel) steadily increased. It therefore became imperative that the
residues be upgraded to the much needed middle distillates and for this purpose a distillate
hydrocracker installed in the Gujarat Refinery.

Process Licensor
For G.R. Hydrocracker, process licensors are M/s. Chevron Research Co., U.S.A. The
Hydrocracking process of CRC is called ISOCRACKING.

Products
Primary function Hydrocracker unit is to maximise middle distillate production in Gujarat
Refinery. Feed to the unit consists of Vacuum gas oil (VGO) from new feed preparation unit
(FPU) which is nothing but a vacuum distillation unit processing the North Gujarat Reduced
Crude Oil.
The primary products from HCU are:
L.P.G
Stabilised Light Naphtha
Heavy Naphtha
Aviation Turbine Fuel (ATF)/ Superior Kerosene (SK)
High Speed Diesel (HSD)

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HYDROCRACKING PROCESS CHEMISTRY

ISOCRACKING REACTIONS
Examples of the principle hydrocracking reactions taking place in the ISOCRACKER are
given below. All of these reactions are exothermic. In general, sulfur and nitrogen molecules
are cleaved from the sulfur-or nitrogen containing hydrocarbon ring by saturation (of the
ring) and hydrogenation to yield H2S and NH3. Cracking reactions conserve rings to a great
extent. Occasionally, there are more product molecules with rings than feed molecules.
Product paraffins tend to be branched chains with only minor amounts of normal paraffins.
To a great extent, the olefin saturation occurs early in the progress of the reactions through
the reactor.
Desulfurization
The fresh oil feed is a desulfurized by hydrogenating sulfur containing compounds to yield
hydrogen sulfide. The hydrogen sulfide is subsequently removed from the reactor effluent,
leaving only the hydrocarbon in the product. Typical desulfurization reactions convert
thiophenes or thiols to straight chain or branched paraffins and hydrogen sulfide. The heat of
reaction for desulfuization is about 565 kcal/Nm3 (60 Btu/SCF) of hydrogen consumed.
R ----- C ----- CH
HC

CH + 4H2

CH 3- CHCH2CH3 + H2S
Catalyst

S
Thiophene

Branched Paraffin

R
R- - - - - - CH - - - - - SH + H2

R - - - - - CH2 - - - - R + H2S
Catalyst

Thiol

straight-Chain
Paraffin

Denitrification
Nitrogen is removed from the feedstock by hydrogenating nitrogen containing compounds to
form ammonia. The ammonia is subsequently removed from the reactor effluent, leaving only
the hydrocarbon in the product. Typical ISOCRACKING reactions with nitrogen compounds
include hydrogenation of pyridines to form paraffins and ammonia, quinolines to form
aromatics and ammonia, and pyrroles to form paraffins and ammonia. The heat of reaction of

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the denitrification reactions is about 630 705 kcal/Nm3 (67-75Btu/SCF) of hydrogen

consumed.
R-CH2 -CH2- CH2 NH2 + H2

R-CH2 CH2 CH3 + NH3

Catalyst

Amine

Paraffin

Saturation of olefins and aromatics

Hydrogenation of olefins is one of the most rapid of the reactions taking place. This rapidity
is the reason essentially all olefins are saturated. The heat of reaction for these reactions is
about 1320 kcal/Nm3 (140 Btu/SCF) of hydrogen consumed.
R - - - - - CH2CH=CH2 + H2

R - - - - - CH2CH2 CH3
Catalyst

Olefine

Paraffin

Aromatics Saturation
Some of the aromatics in the feed are hydrogenerated to naphthenes.
Aromatic saturation accounts for a significant portion of both the total hydrogen consumption
and the total heat of reaction. Heats of reaction vary from about 375-750 Kcal/Nm3 (40-80
Btu/SCF) of hydrogen consumed depending on the type of aromatic being saturated. In
general, higher pressures and lower temperature result in a greater degree of aromatic
saturation.

RC

CH2
CH + 3 H2

C
H

CH2

H2C

C
H

CH2
CH2

Aromatic

CH2

Naphthene

Hydrocracking
Hydrocracking of large hydrocarbon molecules into smaller molecules occurs in nearly all
processes carried out in the presence of excess hydrogen. The heat release from the
hydrocracking reactions contributes appreciably to the total heat liberated in the reactor. Heat
of reaction are of the magnitude of 470 kcal/Nm3 (50 Btu/SCF) of hydrogen consumed.
Small amounts of Naphtha and light hydrocarbons are produced, and some cracking reactions
involving the heavy molecules contribute to a decrease in specific gravity. The light

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hydrocarbon yields are temperature dependent. Thus, the amount of light ends produced
increases significantly as temperatures are raised to compensate for reduced catalyst activity.
Paraffins are believed to crack by the following mechanism:
1. An olefin is formed by dehydrogenation of a paraffin on a metal site.
2. The olefin is absorbed on an acid site to form a carbonium ion.
3. The carbonium ion isomerizes to a more stable carbonium ion (tertiary).
4. The carbonium ion cracks to an olefin and a smaller ion.
5. The cracked olefin ion cracks to an olefin and a smaller ion.
6. The cracked olefin is saturated on a metal site to form an isoparaffin.
This helps to account for the low concentration of normal paraffins in hydrocracked products.
Isoparaffins react much faster than normal paraffins because they are more easily converted
to the olefin intermediate.
Naphthenes crack by more complicated reactions than paraffins. A typical naphthene reaction
is the so called pairing reaction in which methyl groups are paired off from naphthene rings
to form isobutane while leaving the ring itself intack. This complex reaction almost always
produces isobutane and five or six membered naphthene ring which contains four less carbon
atoms than the reactant molecule. Other naphthene reactions include simple cleavage of four
carbon or longer side chains from the ring and, less commonly, ring opening.
Aromatic reactions are the most complex of all. Alkyl aromatics undergo simple cleavage of
four carbon or longer side chains, or two alkyl aromatics undergo a disproportionation
reaction to form benzene and an alkyl aromatic with two side chains. With longer side chains,
cyclization occurs to form a product molecule with two fuse rings like tetralin. Aromatics
with methyl side groups also undergo the same kind of paring reactions as naphthenes.
Polycyclic aromatics like phenanthrene undergo two distrinctly different kinds of reactions.
In one, the central ring saturates and opens up to yield two single ring naphthenes. In the
other, a complex reaction proceeds as follows:
Partial saturation, followed by opening of one of the saturated rings to form a butyl side
chain.
Transfer of the side chain to another reactant molecule (assume phenanthrene).
Ring closure of the side chain to form a four ring compound with two unsaturated central
rings.
Cracking of one of the central rings to give tetralin and a single ring naphthene.

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Catalyst Chemistry
Hydrocracking catalyst are dual functional, which means that they have both acid cracking
sites and metal hydrogenation sites. The hydrogenation sites provide olefin intermediates and
saturates olefin products. They saturate some of the aromatic rings and prevent the
accumulation of coke on the acid sites by hydrogenating coke precursors. The acid sites
provide the carbonium ion intermediates and the isomerisation activity that result in the
dominance of isoparaffin products. More acidic catalysts produce a lighter yield distribution
of higher iso-to-normal ratio products. Higher hydrogenation activity catalysts produce more
saturated products with a heavier yield distribution.
Catalyst Sulfiding
Sulfiding is done to regenerate the strong acid sites on the catalyst which were neutralised by
nickel salts during catalyst manufacture. An unsulfided catalyst has much lower cracking
activity and produces products of low iso-to normal ratio.
Sulfiding itself proceeds as two separate reactions.
The cracking of DMDS:
CH3-S-S-CH3 + 3H2
2CH4 + 2H2S
Followed by the sulfiding proper:
2H2S + 3 NiO + H2

Ni3S2 + 3 H2O.

Catalyst Regeneration
Catalyst Regeneration consists primarily of burning off accumulated coke on the catalyst
during the oxidation phase :
4C1H1 + SO2

4CO2 + 2H2O

As an unwanted side reaction, some of the sulfur (from sulfiding) is also oxidised:
Ni3S2 + 4O2

NiSO4 + 2NiO + SO2

To yield nickel sulfate, nickel oxide, and sulfur dioxide. In the reduction phase, the nickel
sulfate is eliminated to prevent temperature runaway during subsequent sulfiding:
3NiSO3 + 10H2

Ni3S2 + SO2 + 10H2O

Since some of the sulfur is retained as nickel sulfide, the subsequent sulfiding uses less
DMDS than used for sulfiding of fresh catalyst.
As a side reaction during reduction, metal oxides are converted to metals:
NiO + H2

17

Ni + H2O

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PROCESS DESCRIPTION
Brief Description
In Hydrocracker, the VGO feed is subjected to cracking in 2 stage reactors over catalyst beds
in presence of Hydrogen at pressure of 170 kg/cm2 & temperature raging from 365 to 441
deg. C. The cracked products are separated in fractionator. Light ends are
recovered/stabilized in debutanizer column. The process removes almost all sulfur and
Nitrogen from feed by converting them into H2S & Ammonia respectively. Thus the products
obtained are free of sulfur & nitrogen compounds and are saturated. Therefore, except for
mild caustic wash for LPG, post treatment is not required for other products.
The unit consists of the following sections:
(i)
(ii)
(iii)
(iv)

First stage Reactor section

Second stage Reactor section
Fractionation Section
Light Ends Recovery section

FIRST STAGE REACTOR SECTION

Vacuum Gas oil feed is supplied from FPU and heated in exchangers and brought to the
pressure of 185 Kg/sq.cm by feed booster pumps. It is mixed with recycle Hydrogen and pure
Hydrogen from make-up compressors and further heated in reactor effluent exchanger
followed by furnace upto 385 Deg. C before it enters the First Stage Reactor.
The first stage reactor contains three catalyst beds with two intermediate quench zones which
use recycle gas as quenching medium. The reactor effluent is cooled in exchangers, steam
generators and finally in an air fin cooler upto 65 deg. C. It is flashed in the High Pressure
Separator (HPS) from which Hydrogen Rich gas is recycled back to the reactor.
The liquid product from the separator flows through a Power Recovery Turbine (PRT) to the
Cold Low Pressure Separator (CLPS). The first stage reactor converts approximately 40% of
the feed to middle distillates and lighter products.
SECOND STAGE REACTOR SECTION
Converted feed from the first stage reactor is removed in the fractionator section and
unconverted material from the first stage forms the feed to the second stage.
Feed from vacuum column bottom is boosted upto 185 kg/cm2 and mixed with recycle gas
and pure hydrogen from make up compressors and is heated in the reactor effluent exchanger
followed by 2nd stage reactor furnace upto 345 Deg. C before it is sent to the reactor.

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This reactor also contains three catalyst beds with two intermediate quench zones which use
recycle gas as quenching medium. The reactor effluent is cooled in the exchangers, steam
generators upto 204 deg. C and is fed to Hot High Pressure Separator (HHPS)
Liquid from HHPS flows through a power recovery turbine, which drives the feed pump, and
goes to Hot low pressure separator (HLPS) before going to fractionation section.
The hydrogen rich gases are cooled in exchangers followed by air cooler upto 65 deg. C
before entering into Cold High Pressure Separator (CHPS).
FRACTIONATION SECTION
Liquid from HLPS is heated in the exchangers and finally in a furnace upto 345 Deg. C
before it is sent to fractionator column. The overhead products are off-gases and light
naphtha. Off gases are washed with Amine to remove H2S and are sent to the Fuel Gas
System.
Heavy Naphtha is withdrawn at 146 Deg. C as first draw off. It is stripped in a stripper and
cooled before it is sent to storage.
The second draw off is ATF at 188 Deg. C. It is stripped and then cooled in feed exchanger,
steam generators followed by coolers before it is sent to storage.
The third draw off is HSD at 286 Deg. C. It is also stripped in a steam stripper, cooled in
steam generator and water cooler before it is sent to storage.
The bottom of the fractionator is pumped to Vacuum Column. The bottom temperature of the
column is maintained at 377 Deg. C using a reboiler furnace. HSD is withdrawn as a side cut
of vacuum column and blended with diesel from fractionator after cooling in exchanger and
cooler. The bottom of the vacuum column is feed for second stage reactor.

LIGHT ENDS RECOVERY SECTION

Light Naphtha from the fractionator is sent to deethaniser, where gases are removed and sent
to Amine Absorber where the H2S is absorbed in the Amine and H2s free fuel gas is sent to
Fuel Gas system. Rich amine with dissolved H2S is sent to Amine Regeneration Unit in
Sulfur Recovery Unit Block. The bottom of deethaniser is sent to debutaniser, for the
recovery of LPG. LPG is taken out from the top and sent to treating section where it is
washed with caustic for removal of H2S. The stabilised Naphtha from the bottom of the
stabilizer is sent to Hydrogen Unit for production of Hydrogen.

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CRITICAL EQUIPMENTS

REACTOR
Reactor is the core of the hydrocracker unit. It is filled with catalyst. Hydrocracking reactions
are made to occur here by providing the necessary pressure and temperature conditions.
Mechanical Details
Reactor is a cylinderical vessel with dished ends. The total height of the cylindrical portion is
16 meters and internal diameter is 3.35 meters. The shell thickness is 228 mm and its weight
is approximately 400 MT. There are total two reactors one in each stage of the hydrocracker
unit. It is supplied by M/s. Larsen & Toubro.
Metallurgy
The reactor is made of high grade low alloy steel with base metal of 2-1/4 Cr-1 Mo to prevent
damage from hydrogen at high temperature and pressure condition. Welding overlay cladding
of 6 mm in two phases have been given to shell and heads. First part of 3 mm dia with SS 309
and 2nd pass of 3 mm dia with SS 347. The reactor internals are made of type 347 SS.
Screens and space cloth are also made of type 347 SS.
Operating/Design Parameters
It has been designed to withstand the severe operating conditions with respect to temperature
(340 deg.C - 440 Deg. C) and pressure (170 kg/cm2g). The design temperature and pressure
of the reactor is 454 deg. C and 190 kg/cm2g respectively.

Functional Details
The function of the reactor and its internals is to support the hydrocracking reactions at a
controlled rate. The reactor is divided into three beds of catalyst with a quench stream
injection in between two beds which limits the temperature rise in the beds. The quench
stream also helps in proper distribution of the reactants and supplementing the consumed
hydrogen in the reaction apart from acting as a heat sink. The successive catalyst bed is made
deeper than the last to keep the individual bed temperature rise about equal i.e. about 28 deg.
C.
The feed is made to pass through the basket, fine screen and perforated plate successively.
This helps in retaining oversized debris on fine screen and good distribution across entire
reactor cross section.

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The liquid from the perforated plate falls on the chimney tray below. The liquid flows
through small holes in the side of the chimneys. Holes are sized such that there is a liquid
hold up of about 100 mm to 150 mm on every tray which helps in equalising the liquid flow.
Vapour from perforated plate flows to the top of the chimney down through its core to the
catalyst bed below. The bed is supported by a multilayer system of support with a 150 mm
deep layer of support catalyst (ICR-114ZF) resting on top of the screen.This is a large dia
catalyst appr. 4.2 mm dia whose purpose is to keep small dia active catalyst from plugging
the screen.
The active catalyst rests on top of the support catalyst. It is loaded to within 125 mm of the
chimney tray.
The quench gas is injected below the bed support beams. The quench gas enters through the
side of the reactor and flows through a pipe to the quench ring. Quench ring is concentric
with the reactor. Quench gas flows at a high velocity through small holes in the quench ring
to mix with and cool the downflowing fluid. Quench ring ensures even distribution of quench
gas across the reactor cross section.

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Instrumentation
To monitor the temperature profile inside the reactor, bed thermocouples are provided in
three radial positions at the top and bottom of each bed.
Temperature measured at different heights but at the same circumferential position are used
for bed temperature control. Temperature measured at the same height but different
circumferential position in the bed will indicate location and possible channeling of the
reactants.
The temperature controllers that regulates the quench gas flow are:
TEMPERATURE CONTROLLERS
Between bed
1-2
2-3

First Stage

Second Stage

TDIC-3528
TIC-3533

TIC-5228
TIC-5233

Normal fresh feed catalyst pressure drop across the reactor is estimated to be 4.7 kg/cm2.
During the operating life of the catalyst charge, pressure drop may increase if particulates
accumulate. Pressure taps are provided on the feed line, quench lines & the effluent line from
the reactor. All taps are manifolded to allow pressure drop measurement between any of these
points.
Projection
The skin thermocouples have been provided at three locations circumferentially at two
different heights of the each catalyst bed to monitor the shell heat up and cool down rates.
Skin thermocouples are also provided at the nozzles of the reactors, bottom dished end of the
reactor and the support skirt of the reactor to check the metal temperature for reactor
protection. There are total 27 no. of skin temperature indicators.
L.P. steam ring is provided across the top and bottom nozzle flange connections to safeguard
against possible leakages and fire at the flange joints.

FIRST STAGE AND SECOND STAGE CHARGE HEATERS

These are natural draft twin cell box type furnaces with horizontal tubes. The heaters are an
upright steel structure with a casting of carbon steel material. The casing is lined with 200
mm thick ceramic fibre on the inside. Heaters bottom and convection sections are refractory
lined.

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The combustion chamber houses the radiant section tubes. In this section heat is transferred
primarily by radiation from the flame and the hot combustion products. The convection
section is provided on top of the radiant section and serves to increase thermal efficiency of
the furnaces by removing further heat from the flue gases leaving the radiant section. The
convection section consists of steam generation coils and steam super heater section. No
hydrocarbon coils are provided in the convection section because the feed (VGO + recycle H2
gas) enters the furnace at high temp (=3630C) and convection section is not able to add any
heat to the feed. The feed to be heated enters the radiation section in two passes (1 pass for
each cell.) The coils are of SS-347 material. Feed passes out of the radiant section and joins
together outside the furnace and enters the transfer line. The radiation coils are of 193 mm
OD and 17.78 mm thick and are installed in the centre of each cell in one row of 10 tubes.
The burners are installed on the radiation coils. There are 12 nos. of burners on each side
with a total of 24 burners for each cell and 48 burners for each heaters.
The convection section for first stage furnance consists of steam generation section with 24
nos. of finned tubes of 88.9 OD and 7.69 mm thick and 8 nos. of bare tubes of carbon steel
material. The fins are 25.4 mm high and 1.5 thick of CS material. The convection section for
second stage furnance is provided with steam generation and steam super heating coils. The
fins are of 25.4 mm high and 1.5 mm thick of CS. Only fuel gas is envisaged to be burnt in
these heaters and no soot blowers are provided.
The hot flue gases from both the heaters will go to a common stack located in between the
two furnaces. Dampers are provided on flue gas duct from each furnace before they join the
common stack. The dampers can be operated from the grade. The draft gauges & sample
nozzles are provided in the heaters to measure draft and take flue gas simples respectively.
SO2 analyser is provided on the stack for continuously monitoring SO2 emission from the
furnaces.
Snuffing steam connections are given as fire protection both in convection and radiation
zones. As per CRC practice a rupture disc is provided between the snuffing steam nozzle and
piping to avoid corrosion of the piping. Rupture disc is to be installed again after furnace
startup.
Necessary stubs are provided on inlet and outlet of hydrocarbon coils for installing decoking
facility in future if necessary.
Thermocouples are provided in the radiation and convection section for monitoring
temperature in the heater. Skin thermocouples are mounted on the bottom of the furnaces
instead of on the side walls unlike other heaters.

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COMPRESSOR
Compressors used are a barrel-type centrifugal compressor. The rotating element consists of
six stages of compression and a balance drum designed to oppose the axial thrust force
created by impellers. Leakage around the balance drum is minimized by very close
tolerances. This leakage is collected in the cavity behind the drum and is piped back to the
suction of the compressor. The rotating shaft of compresssor is sealed hydraulically with oil
through a system of close tolerance labyrinths which prevent compressed gas form leaking to
the atmosphere.

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Some of the more important operating data for compressor are as follows.
Rated rpm

10,790

Maximum continuous speed, rpm

12,463

Trip Speed, rpm

13,708

Maximum Compressor Discharge Temperature, 0C

88.5

Maximum Lube oil outlet Temperature, 0C (Design)

57

Compressor Turbine
It is a seventeen stage Nuovopignone steam turbine driver. It uses 12 kg/cm2 steam as its
driving force, exhausting to a surface condenser system. The shaft is sealed by a system of
labyrinths and carbon ring to steel face seals. An ejector system educts and condenses minor
steam leakage. This ejector system is discussed in Section 13.4.1.6.(B)
Governor Control System
The speed of turbine is controlled by a hydraulic governor system which maintains the speed
of the unit under varying load conditions. The oil supply for governor operation is supplied
directly from the main lube oil pump at about 11 Kg/cm2. Oil to the governor system
supplies motive force for three purposes.
1.

Oil pressure on the trip throttle valve latching mechanism holds the hook in a latched
position so the valve can be reset and opened manually. On loss of oil pressure, this
latch dumps and the trip throttle valve closes, stopping the turbine.

2.

Oil pressure operates the oil relay which sets the position of the governor valve (steam
inlet) base on the machine rpm.

3.

Oil pressure loads the dump valve mechanism on the overspeed trip. On overspeed,
this mechanism will dump the lube oil which in turn will trip the latch on the trip
throttle valve and the trip throttle valve will close. Loss of lube oil pressure (from the
same pump as governor oil but regulated to about 2.5 kg/cm2 will also trip the trip
throttle valve and shut the machine down. KT-001 overspeed trip is a system of
flyweights which opens a governor oil dump valve when a preset rpm is reached.
When the dump valve opens, oil pressure is lost to the trip throttle valve and shuts the
machine down.

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Turbine Seal Leakoff Ejectors

To prevent steam from leaking around the shaft seal glands on the turbine, a system of
sealing steam is used. Connections to both the inboard and outboard seal labyrinths allow
condensate and some steam to be drawn through the EE-101 surface condenser. The driving
force for this seal is steam at 12 kg/cm2.

REACTOR FEED PUMPS

These pumps are 10 stage, high speed, single flow, horizontal type pumps and are
manufactured by INGERSOLL-RAND, U.K. These pumps are driven by 2200 hp/6.6 KV
ALSTHOM motors. The primary pump has power recovery turbine connected to the motor
(PM-002A and PM-005A) with a clutch. This power recovery turbine reduces the power
consumption by unloading the motor, about 30-35%.
Feed Pump
These are 10 stage, horizontal type pump. (These pumps have volute and single suction first
stage impeller). All impeller inlets are facing in the same direction and the impeller thrust is
neutralised by a differential pressure device known as a balancing drum. The balance drum
equalize the impeller's axial thrust with external balance line connected to the pump suction
line. The balance actual thrust is taken by the main bearing.
Pump design & operating parameters are shown below:

Pump type
No. of stages
Flow rate (at flow temp.)
Operating pressure
Flow temperature
Sp. Gravity at PT
Efficiency
RPM
Viscosity at PT
Minimum flow at flow temp.
Type of seal
Seal flush
Bearing

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3 x 11 CB -10
10
Normal 189.4 m3/hr
Design 208.3 m3/hr
Suction 6.5 kg/cm2g
Discharge 184.4 kg/cm2g
Normal 2000C
Design 2880C
0.792
73%
4650
3.92 cp
92.0 m3/hr
Mechanical "Sealol"
FLO (HSD)
Michell thrust

Gujrat Refinery

Power Recovery Turbine

A power recovery turbine is provided in the feed pump system to share part of the power
(about 30-35%). The balance power is supplied by the motor. Liquid from the hiugh pressure
separator at 156 kg/cm2 is put this through a power recovery turbine to recovers large
amount of horsepower. The turbine shaft (which is coupled to motor through a clutch) puts
energy back into the system and saves electrical energy. The turbine acts like a centrifugal
pump in reverse (high pressure suction, low pressure discharge). When turbine is running at
design conditions, it will deliver 618 horsepower (461 BKW) into the motor. The turbine for
1st stage is 10 stage & for 2nd stage is 12 stage & are horizontally split, single case opposed
impeller pump. Both turbines are designed to run at the motor speed of 2970 RPM. They are
single flow type i.e. all runners face in one direction only.
The power recovery turbine design parameters are given below:
1st stage
3x11 CBT-10
156 kg/cm2
35 kg/cm2
650C

Size & Type

Inlet pressure
Design outlet pressure
Normal flow temp
BHP recovered rated 2970
RPM

2nd stage
3x11 CBT-12
156 kg/cm2
35 kg/cm2
2030C
2970

VALVES

Globe valves
A globe valve is a type of valve used for
regulating flow in a pipeline, consisting of
a movable disk-type element and a
stationary
ring
seat
in
a
generally spherical body.

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Safety valve
A safety valve is a valve mechanism which
automatically releases a substance from
a boiler, pressure vessel, or other system,
when the pressure or temperature exceeds
preset limits.

Needle valve
A needle valve is a type
of valve having a small port
and a threaded, needleshaped
plunger.
It
allows precise regulation
of flow, although it is
generally only capable of
relatively low flow rates

Solenoid valve
A solenoid valve is
an electromechanically operated valve. The valve
is controlled by an electric current
urrent through
a solenoid: in the case of a two-port
two
valve the flow
is switched on or off; in the case of a three-port
three
valve, the outflow is switched between the two
outlet ports. Multiple solenoid valves can be
placed together on a manifold.
Solenoid valves are the most frequently used
control elements in fluidics. Their tasks are to shut
off, release, dose, distribute or mix fluids. They
are found in many application areas. Solenoids
offer fast and safe switching, high reliability, long
service life, good medium compatibility of the
materials used, low control power and compact
design. Besides the plunger-type
type actuator which is
used most frequently, pivoted--armature actuators
and rocker actuators are also used.

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Pneumatic actuated control valve

In this type of valve, air

pressure is applied through
a pilot valve into the
actuator which in turn
raises the diaphragm and
opens the valve. This type
of valve is one of the more
common valves used in
operations where valve
speed is a necessity.

No return valve
A check valve, clack valve, non-return valve or one-way
valve is a mechanical device, a valve, which normally
allows fluid (liquid or gas) to flow through it in only one
direction.

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PRODUCT ROUTING AND LINE SIZING

Hydrocracker unit produces Fuel gas, LPG, Naphtha, ATF/SK and HSD as products. Routing
of these products and their destination is described below:

1) Fuel Gas
Fuel gas from KOD of H2S absorber is routed to Fuel Gas system in FPU through a
dia 6" line.
2) Light Naphtha
Light naphtha is routed to naphtha storage tanks for use as H2 plant feed through a dia
4" line.
3) Heavy naphtha
Heavy naphtha will be normally blended with HSD at HCU. However, it can be
routed to refinery along with Light naphtha. Provision of routing heavy naphtha to
CRU also exists.
4) LPG
LPG produced in the HCU can be routed to fuel gas system of FPU through a dia 2"
line or it can go to Horton spheres in the LPG area of refinery through a dia 4" line.
5) SK
SK from HCU goes to existing Refinery area through a dia 6" line. Hook-ups are
provided to route it to either GRE SK rundown or SK tanks.
Provision
of
routing SKO to HSD header inside the B/L also exists.
6) ATF
ATF goes through a dia 6" line to the refinery area. Hook-ups are provided in the
Refinery area to route it to ATF tanks
7) HSD
HSD is let down through a dia 6" line which goes to Refinery area. A separate dia 4"
line goes to power plant of GHP. Another dia 4" line is available to route it to FLO
drum located in FPU. Provision of routing HSD to 12 HSD header at B/L also exists.

All the lines are connected to a dia 6" slop line at the battery limit which in turn
connected to dia 10" slop header going to dry slop tanks. Dia 1 1/2 " LP steam
connections are provided near battery limit for flushing purpose. All the lines are
provided with a double block valve and spectacle blind for positive isolation during
shut-down.

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INSTRUMENTATIONS

DISTRIBUTED DIGITAL CONTROL SYSTEM

The instrumentation and control system installed in Hydrocracker Plant is Distributed Digital
Control System TDC - 3000 of M/s. Tata Honeywell make. This is a very versatile control
system and has lot of advantages over conventional control system. The advantages include
flexibility of control, ease of operation and maintenance, high reliability, good presentation of
data in the form of various displays etc.
The DIDC System comprises of the following subsystems.
1)

Controller subsystem for closed loop controls.

2)

Data acquisition subsystem for open loops.

3)

Programmable logic controller (PLC) sub system for interlocks.

4)
systems

Communication subsystem for the communication between various sub

5)

Operator interface subsystem for operator interaction with Process.

6)

Engineering console for system configuration.

7)
The various Peripheral devices include Printers, Video Copiers, Assignable
trend recorders etc.
The system architecture of TDC - 3000 used for Hydrocracker controls is shown in Fig. (i).
A brief description of various subsystems is given below :ADVANCED MULTIFUNCTION CONTROLLER (AMC)
This is used for closed loop control in the system. Each AMC controls 16 closed loops and
has a redundant card to take care of failure of active card. The AMC is connected to the
Universal Station (US) on the local control Network (LCN) through the Hiway Gateway
(HG) and Data Hiway. Battery Protection for AMC memory (RAM) is provided to retain the
memory of the controller in case of power failure.

INDUSTRIAL PROGRAMMABLE CONTROLLER (IPC)

This is used for data acquisition of various system variables like indicators, annunciators, etc.
like AMC, redundancy is provided in IPC to take care of card failure. Various signals
connected to IPC are analog, digital signals etc. Battery protection for IPC Memory (RAM)
is provided to retain the memory in case of power failure.

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CRITICAL PROCESS CONTROLLER (CPC)

This is used for performing interlock functions. This is a triple redundant programmable
Process controller having three independent power supply and three Processors. This works
on two out of three voting logic i.e. for any failure of single processor, operation is not
interrupted.
UNIVERSAL STATION (US)
This is the Man Machine interface on TDC-3000 System and provides single window access
to the entire Plant. This is a node on the LCN and has access to the entire system. This is a
full color graphic CRT with touch screen facility.
Interaction with Process is done through graphics/group displays using touch screen and
membrane keyboard. The various displays available are Group display, graphic display,
detail display, Area and Unit trend display, overview display etc. Copies of Typical displays
are given in figures.
HISTORTY MODULE (HM)
This is used for storage of information like system database. Process History, Process events,
logs/reports etc. The memory capacity of HM is 140 MB with two winchester discs and has
double drives.
APPLICATION MODULE (AM)
This is used for incorporating advanced control and optimisation strategies and has a memory
capacity of 2 MB.
COMPUTER GATEWAY (CG)
This is an interface for networking TDC-3000 to Higher level computers (Microvax) for
Plant optimisation and as a supervisory computer.
HIWAY GATEWAY (HG)
This is the link between LCN and Data Hiway. The information about all tags is resident on
Hiway Gateway.

LOCAL CONTROL NETWORK (LCN)

This provides communication link between all the nodes (AM, US, HG, HM etc.) and is a
redundant pair of Coaxial Cables.

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ENGINEERING CONSOLE
This is used for System configuration, graphic page compilation, system maintenance and
diagnostic etc.
PRINTER
This is a Serial Printer for data logging/report generation purposes.
ALARM & EVENT PRINTER (AEP):
This is used for printing alarms generated in the Process, printing events like Plant shutdown, information about changes made in mode of controllers etc.
ASSIGNABLE TREND RECORDER (ATR)
This is a six pen recorder where the selection of tags for continuous recording can be
assigned from the operator console (US).

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SAFETY MEASURES ADOPTED

Safety should never be taken for granted anywhere in the refinery. Workers life and the
healthiness of the equipment depend on your alertness. Carelessness causes the accidents.
Some of the general safety measures adopted are:

Plant and equipment safety

For vessels and reactor
Level controller
Level controllers are installed on vessels to monitor liquid level. They are also cascaded with
flow control valve which closes automatically at high levels. High and low level alarms are
also provided.
Temp controller
Similar to level controller, temp. indicator are also provided in certain vessels, like reactor,
feed surge drum to maintain its temperature by controlling the cascaded flow valve allowing
or stopping hot input. High-low temp. alarms are also provided.
Pressure safety valve
In pressure vessels like reactor, pressure safety valves are provided to release excessive
pressure in emergencies and upsets and thus preventing explosion. High-low pressure alarms
are also provided.
Rundown and bypass system for emergencies
A rundown system is also provided to drain reactor content in case of emergencies like fire or
leakages to avoid fire and explosion. Bypass system is also there to treansfer feed to other
units like FCC in case of shutdown.
For pipelines
Steam rings
As hydrogen is colourless gas its leakage through flanges is very difficult to detect. So steam
rings are provided which facilitates easy detection and also prevents leakage to some extent.
Alternative lines
Alternative lines are also provided for emergency leakages.

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Flushing system
Steam flushing system is also there to remove any trapped hydrogen pockets in pipe, valves
or bends which may cause fire.

For compressor and pumps

Self actuated valve
Self actuated valves are provided before compressors and pumps which closes automatically
in case of high pressure or over heating. Non return valves are provided at output line to
avoid back flow.
Tripping interlocks
Various interlocks are provided which trips the pump/compressor, high pressure in reactor,
high temp. in reactor, less pressure in output line due to leakage or over heating to avoid
damage to pump and other equipments.
By pass line and Stand by
Incases of pump/compressors failure, by pass lines are provided to root input to standy pump.
For workers health
Nitrogen purge for pyrophoric catalyst
Unregenerated, spent catalyst continually evolves adsorbed hydrocarbons. To preclude the
formation of an explosive hydrogen-oxygen mixture in the reactor a continuous nitrogen
purge should be maintained over the spent catalyst throughout the catalyst dumping
procedure or until the reactor is flooded with water.
Prevention of H2S poisoning
H2S detector should be used. When drawing samples, venting instruments, bleeding pumps,
etc. precautions should be taken to avoid breathing the vapours. Gas masks suitable for use
with H2S are available and must be used when repairing equipment containing appreciable
amounts of H2S. Men should work in pairs. Canister masks must be checked frequently to
make sure that they are not exhausted. If work should ever have to be done inside equipment
containing any H2S, a fresh air mask with continuous air supply must be used.

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Fire Prevention Activites :

Fire prevention can best be achived with the application of :
1. Sound engineering :
2. Design of the plant materials used for construction, means of escape etc.
3. Good housekeeping :
4. Cleanliness of the plant, methods of storage.
5. Good habits:
6. Observation of fire prevention rules etc.
7. Common sense
8. No smoking near inflammable material etc.
9. Instruction to personnel :
a. Knowledge of the job.
b. Safe practices.
c. Action in case of fire.
d. Knowledge of fire extinguishers etc.
10. Regular training of employees:
Introduction training program
Refresher courses
Specialised Training programs
11. Safety audits :
# Internal * External

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