1. Haldia Refinery Presentation on LOBS.
Hirak Dutta, General Manager(Technical)
Haldia Refinery

2. LUBRICANTS LUBRICANTS = BASE OILS + ADDITIVES
BOTH MINERAL AND SYNTHETIC BASE STOCKS AND THEIR MIXURES ARE USED IN LUBRICANT FORMULATION
MINERAL OILS PRODUCED / REFINED FROM CRUDE OILS ARE SINGLE COMMON SOURCE OF BASE STOCKS.
LUBRICATING PROPERTIES OF BASE STOCKS ARE INFLUENCED BY
 CRUDE SOURCE
 REFINING PROCESSES

3. USE OF LUBRICANTS/BASE OILS
ENGINE OILS
GEAR OILS
TRANSMISSION FLUID
INDUSTRIAL APPLICATION
CATALYST CARRIER OILS.
WHITE OIL APPLICATION

4. FUNCTION OF LUBRICANTS
MINIMISE FRICTION AND WEAR
REMOVAL OF DEBRIS
DISSIPATION OF HEAT
ACT AS ELECTRIC INSULATOR
PREVENTS RUSTING & CORROSION

5. LUBE BASE OILS FORMULATION OF LUBRICATING OILS HAS
BECOME VERY COMPLEX-
OEM ( ORIGINAL EQUIPMENT MANUFATURER) REQUIREMENT
GOVERNMENT REGULATION
EFFICIENT USE
ENERGY CONSERVATION
ENVIRONMENT CONCERN
CHANGING PRODUCT SPECIFICATIONS
EXPANDING VAST MARKET.

6. REQUISITE PROPERTIES APPROPRIATE VISCOSITY HIGH VISCOSITY INDEX
LOW POUR POINT
LOW VOLATILITYAND HIGH FLASH POINT
GOOD THERMAL AND OXIDATION STABILITY
HIGH HEAT CAPACITY GOOD THERMAL CONDUCTIVITY
NON CORROSIVE, OILINESS AND WETABILITY

7. LUBE BASE OILS
ALL BASE OILS DO NOT POSSESS SIMILAR PHYSICO CHEMICAL PROPERTIES OR PROVIDE EQUIVALENT ENGINE OIL PERFORMANCE.
API ( AMERICAN PETROLEUM INSTITUTE) CLASSIFIED ALL BASE STOCKS IN FIVE GROUPS ON THE BASIS OF
SATURATES
VISCOSITY INDEX(VI)
SULFUR CONTENT

8. API BASE OIL CLASSIFICATIONVI
SATURATES %
SULPHUR
GROUP I
80-100
<90
>0.03
GROUP II
80-120
>90
<0.03
GROUP III
>120
GROUP IV
POLY ALFA-OLEFINS (SYNTHETIC ORIGIN)
GROUP V
NOT INCLUDED IN ABOVE FOUR – VEGETABLE OILS, ESTERS ETC.

9. LUBE BASE OILS LUBE PROCESSING REQUIREMENT IS A FUNCTION OF
HYDROCARBON STRUCTURE OF
FEED
 TARGET PROPERTIES OF
FINISHED BASE OILS

10. HYDROCARBON STRUCTURE
V I
POUR PT
INTEREST
N-PARRAFIN
VERY HIGH
HIGH
LOW
ISO-PARAFFIN
NAPHTHENE
MEDIUM
AROMATICS
CONDENSED
/POLAR
VERY LOW --

11. Lube Composition and PropertiesVI KV
n - Paraffins
i - Paraffins
mono - Naphthenes
di & higher Naphthenes
mono - Aromatics
di - Aromatics
tri & higher- Aromatics VI
Pour Point
Molecular weight

12. Lube Base Oils – PROCESSING:
THREE MAIN STEPS FOR LUBE PROCRSSING:
 LIQ-LIQ EXTRN. TO INCREASE VI
 DE-WAXING TO REDUCE PP
 FINISHING TO IMPROVE
COLOUR AND OXIDATION
STABILITY

13. TREATING / REFINING FOR LUBE PROCESSING
SOLVENT EXTRACTION
SOLVENT DEWAXING
HYDRO-FINISHING
API GROUP I
HYDRO-FINISHING
WAX
SOLVENT EXTRACTION
CATALYTIC DEWAXING
HYDRO-FINISHING
API GROUP I
SOLVENT DEWAXING
SOLVENT EXTRACTION
RAFF. HYDRO-CONVERSION
HYDRO-FINISHING
API GROUP I
HYDRO-FINISHING
WAX
SOLVENT EXTRACTION
RAFF. HYDRO-TREATING
HYDRO-ISOMERISATION
API GROUP I,II
HYDRO-FINISHING
SOLVENT EXTRACTION
SOLVENT DEWAXING
WAX ISOMERISATION
API GROUP III

14. TREATING / REFINING FOR LUBE PROCESSING
LHDC
HYDRO - ISOMERISATION
API GROUP II,III
HYDRO-FINISHING
SOLVENT DEWAXING
FHDC
HYDRO-FINISHING
API GROUP II
HYDRO-FINISHING
WAX

15. Gr I and Gr II Processing - Comparison

16. BASE OIL PRODUCT QUALITY- KEY REQUIREMENTS
Viscosity VI
Pour Point
Colour
Oxidative Stability
Thermal Stability
Anti-Wear Performance
Minimise Sludging
Better Solvency
Lower Volatility
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17. EFFECT OF MANUFACTURING PROCESS ON PROPERTIES OF BASE OILS
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18. API BASE OIL CHARACTERISATION GROUPS
Viscosity Index
Saturates
% wt
Sulphur
%wt
GROUP I
80-100
<90
>0.03
GROUP II
80-120
>90
<0.03
GROUP III
>120
GROUP IV
Poly Alpha Olefins(Synthetic Oils)
GROUP V
All other base oils

19. Haldia Gr-I & Gr-II LOBS
Comparison
Grade
KV (cSt)
VI (min.)
Pour Point (max) GR I
150N
28-32 (40oC)
100 -9
500N
10 (100oC) 95 -6 HN
13.5 (100oC) 92 -3 BN
32 (100oC) II
70N
(40oC)
-21
(40oC)
105
-15
(40oC)
95 (105)
150BS
30 (100oC)

20. Igniting Minds... Energizing Lives…
Gr-I & Gr-II LOBS
Processing: Comparison
Hydro-finishing
Solvent De-waxing
Solvent Extraction
Solvent Extraction
Hydro Treating
Wax Isomerisation
Hydro-finishing
Group-I
Group-II VI
Pour Point
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21. HALDIA LUBE BLOCK

22. Simple Block Flow Diagram of Haldia Refinery
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23. Vacuum Distillation Unit
Purpose:
To Vacuum Distill RCO from Crude Distillation Unit.
Vac.Distillate is feed stock for LOBS units or FCCU.
Products:
GAS OIL Diesel Component.
Spindle Oil ---- Diesel Component or H-70 LOBS feed stock.
Light Oil N grade LOBS feed stock or FCCU feed.
Inter Oil N grade LOBS feed stock or FCCU feed.
Heavy Oil N grade LOBS feed stock or FCCU feed.
Vac. Residu ---- Feed stock for PDA unit.
Quality Monitoring : K. V at 100 0C, Flash Point, Density.
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24. Product Quality of Distillate & Short Residue
Stream
Boiling Range.0C
15 0C
Fl. Point 0C C %S
CCR wt%
Gas Oil
0.8591
119
4 at 37.8
1.38
Spindle oil
0.8992
162
3.54
1.96
Light oil
0.8950
184
3.84
2.38
Inter oil
0.9218
242
10.23
Hy. oil
0.9354
282
21.06
2.4
Short Residue
542+
1.013
342
1075
4.33
14.24
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25. Major Operating Conditions
RCO feed temp : deg C
Preheat Temp : 285 deg C
Coil Outlet Temp : 400 deg C
Vac Tower Flash Zone Pr mm Hg at 400 dec C
Vac Tower Top Temp : 80 deg C
Stripping Steam : Mt/hr
Furnace recycle : 11 m3/hr Pump around : from 300 deg C to deg C
Product Draw off temp : 232 , 245, 333 & 370 for SO,LO,
IO & HO
Bottom Quench : 5 m3/hr
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26. PROPANE DE-ASPHALTING UNIT
Feed Stock:
Vac. Residue from VDU.
Product:
De- Asphalted Oil.
Asphalt for production of Bitumen.
Quality Monitoring:
DAO ---K.V at 100 o C, Flash Point
Asphalt --- Penetration.

27. ROSE : Residium Oil Supercritical Extraction -- Feed & Product Quality
Technology Licensed by M.W. Kellog Technology Co. USA
Design : MT/Yr
Feed Quality : 15.5 deg C : 1.01/1.03
100 deg C : 800/2500
Flash Point : 320 min
CCR , wt % : 20/23
% S : 4.3/4.5
Product Quality : Sp Gr
100 deg C: 30-35/40-45
CCR wt% : 2.2 max
Fl Point, deg C : 320 min

28. Major Operating Parameters- PDA ROSE
Feed Temp : 130 deg C
First & 2nd Dilution : 0.5:1 by volume of propane in each
Total Dilution : 12: 1 (propane : feed by volume
Extraction top Pr : 38 kg/cm2G
Top/Bot temp : 68/52 deg C
DAO separator : 43.6 kg/cm2 g pr. & 102 deg C temp
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29. Extraction Process Best Solvent Property Selective power
High Solvent Power
Low Lt-Hy selectivity and high group selectivity
Boiling point difference with feed
Low melting point
Good gap in density between oil & solvent
Low surface tension
high thermal chemical stability
Low toxicity , Flammability & corrosivity
Low latent heat & sp. Ht
low viscosity at working temp
High bio degradability

30. SOLVENT EXTRACTION UNIT. FEU/NMPEU
Feed stock
Vac. Distillate from VDU & DAO from PDA unit.
Purpose
To extract aromatics from distillates to improve VI of LOBS using Furfural/NMP as solvent.
Products:
Raffinate for further processing of LOBS & Aromatic extract.
Quality Monitoring:
Raffinate: K.V at 100 oC , RI, CCR
Extract : Density.

31. FEU/NMPEU : Yield, Feed & Product Quality, Major Operating Conditions
Raffinate Yield, %wt
52-65
45-55
Feed Rate, m3/hr
50-73
40-50
Extraction temp. Gradient 10
Solvent:Feed Ratio :1
1.93/2.22:1
Top Temp, deg C
95-130
70-95
Bottom Temp, deg C
45-80
60-85
Extractor Pr, kg/cm2g
2.0
Raff/Ext Furnace COT
185/225
270/290
Extract Flash Col Pr.,kg/cm2g
0.5/1.5
0.6/1.2/1.5
Raffinate/Ext. Vaccum Flash Col. Pr, mmHg
200/220
350/300
Water in Solvent
Reduces solvent power
Anti Solvent

32. Solvent De-waxing Unit
Feed Stock :
Raffinate Ex- FEU.
Product :
De-waxed Oil & Slack Wax.
Quality Monitoring:
DWO : Pour Point, Flash Point, KV at 100oC & 40 oC
Slack Wax : Flash Point.

33. Solvent Dewaxing Unit
Objective
To remove paraffinic hydrocarbons to the extend that the Lube based stock produced will have enough low pour point to make it suitable for low temp application
The Process
Extraction and crystallisation to achieve dewaxing with the addition of SDA followed by filtration & Solvent Recovery
Solvent : MEK & Toluene in equal proportions. Toluene is oil solvent & MEK is anti wax solvent.
Feed characterised by density, Kin. Visc & RI
LOBS Product characterised by density, Pour Pt, VI, Flash Point, CCR,Kin Visc.

34. Solvent Dewaxing Unit Good Qualities of Dewaxing Solvent Blends:
High solvent Power for oil & Low Solvent power for wax
Low visc. at operating temperature to get low pressure drop & to help in precipitation /crystallization
Good Filterability
Low Freezing point & temperature effect of Dewaxing
High thermal/chemical stability
Boiling point much lower than that of feed
Low latent heat/specific heat

35. Lube Hydrofinishing Unit
Feed Stock :
DWO from SDU.
Catalyst :
HR 348 supplied by Procatalyse.High purity Alumina extrudates impregnated with Nickel and Molybdenum oxides
Purpose:
To improve color by removing Sulphur,Oxygen & Nitrogen in a reactor with Cobalt / Moly catalyst.
Quality Monitoring:
Color, K.V at 100 oC, VI.
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36. Lube Hydrofinishing Unit
Major reactions : Hydrodesulphurization, Mild hydrodenitrogenation, Olefins hydrogenation, mild aromatic hydrogenation, decomposition of heteromolecules.
Sulphur is usually present as mercaptan, sulphides, disulphide and thiophenic sulphur. Sulphur is removed as H2S.
Nitrogen is usually present as Ammines and pyrrole, pyridine etc. More difficult reaction and ultimate product is hydrocarbon & ammonia.
Olefins are present in low quantity & most of them are saturated during hydro finishing.
Normally aromatics are not hydrogenated. Due to liberation of some aromatics rings towards the light compounds are stripped off to reach the required flash point. Thus results in slight VI improvement also.
Oxygenated compounds are mostly removed in the solvent extraction step. If any remaining removed as water.
As a result, color & color stability improves, mild VI improvement occurs

37. Hydro finishing Unit : Main operating Variables :
Temperature: optimum to achieve desulphurization. Lower the temp, higher is the product viscosity & yields
Partial Pressure of Hydrogen : Increase favors the reaction & reduces coke by avoiding polymerization reaction. Can be modified by change in total pressure and recycle ratio. Total pressure kept maximum compatible with the equipment
Space Velocity : Hourly volume flow rate of feed wrt to the catalyst volume. Lower is the space velocity higher the severity. ( m3 of feed per m3 of catalyst)
Mole ratio of hydrogen/hydrocarbon: Includes quantity needed for hydro finishing + quantity which increases the partial pressure of hydrogen
Feed quality: Higher the impurities higher the severity

38. Hydro finishing Unit Operating Parameters
Reactor inlet temp : deg C
Reactor outlet temp : 360
H2 partial pr. At reactor outlet : 45 kg/cm2g
Space velocity : 0.84 to 1.45 m3 of feed per m3 of catalyst
H2 recycle : 153 liters of pure H2 per litre of oil feed at 15 deg C
Absorber (C-1) : 35.5 kg/cm2g/62.5 deg C
Stripper, (C-2) : 0.25 kg/cm2g /250 deg C
Vacuum Drier (C-3): 50 mm of Hg/249 deg C
1st HP Separator (B-2) : 66.5 kg/cm2g/250 deg C
2nd HP Separator (B-3) : 65.5 kg/cm2g/50 deg C
LP Separator (B-4) : 5.0 kg/cm2g/250 deg C

39. Wax Hydrofinishing Unit
Capacity : T/yr
Feed & Product Quality :
Feed
Product
ASTM Colour
<7.5
<2.0
Sulphur,(wt%)
<0.12(Acidity)
N(ppm)
20-40
Nil
CCR
UV absorbance
<0.02 to < 0.15 at various spectra wave length
Saponification value
<1.0

40. Wax Hydrofinishing Unit
Reactor inlet/outlet pr. : 135.5/134 kg/cm2g
Reactor inlet/outlet temp : 300 def C
Liquid Hourly space velocity : 0.25 hr-1
Hydrogen Partial pressure : 100 kg/cm2g
Hydrogen to Hydrocarbon mole ratio : >500
Hot HP separator : 180 deg C/132 kg/cm2g
COld HP separator : 40 deg C/131.7 kg/cm2g
HP Purge : 36 deg C/66 kg/cm2g
LP Seperator : 185 deg C/6.0 kg/cm2g
LP Purge : 40deg C/4.4kg/cm2g
Liquid in to stripper : 185deg C/0.3 kg/cm2g
Liquid MCW ex drier : 180deg C/0.082 kg/cm2g
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41. HydroTreatment Reactions
Removal of impurities:
Hydro-desulfurization (HDS)
Hydro-denitrification (HDN)
Removal of metals – Ni, V (HDM)
Improvement in quality
Hydrogenation of Olefins (HDO)
Hydrogenation of aromatics – mono & poly (HDA)
Value addition thru’ increase in H:C ratio; Improvement in CCR(%wt.), VI (in case of lube base stock processing)
All these desirable HDT reactions are exothermic

42. HydroTreatment Operating Parameters
-Primary
H2 Partial Pressure
Temperature
LHSV
Secondary
Recycle gas rate
H2S partial pressure

43. Hydro Treatment Operating Parameters Hydrogen Partial Pr.
Also called Cold Hydrogen Partial Pressure. Not a direct operating variable; fixed at the time of design
Defined as the partial pressure of hydrogen in gas phase at the outlet of last reactor.
Under normal operation, depends on:
Total pressure maintained at the HP Separator
Controlled by: Intake of fresh make/up hydrogen in balance with hydrogen consumed in reaction and purged from the system to maintain recycle gas purity
Recycle gas purity
Depends on non-condensable components generated in rxn. which needs to be purged from recycle gas from Recycle Compressor suction

44. Hydro Treatment Operating Parameters LHSV
Liquid Hourly Space Velocity: m3 of fresh feed (at 15°C) per hour per m3 pf catalyst
Significance:
Lower LHSV at design feed rate
Allows greater residence time / contacting time of feed in catalyst. Lesser temperature requirement for same extent of reaction. More cycle life
Requires higher catalyst & reactor volume – higher initial investment
In operation:
Will change with change in feed rate
For consistent product quality, to be compensated by adjusting reactor temperature
Temperature adjustment with change in LHSV as per correlation specified by licensor.

45. HydroTreatment Operating Parameters:Temperature
Temperature - main control variable
Most sensitive effect on reaction severity
Greater variability as compared to other parameters provided by unit design
Action on chemical reactions:
From a kinetic point of view, when temperature increases, the rate of all the chemical reactions increases, i.e. both the desirable and the undesirable reactions.
From a thermodynamic point of view, desirable reactions are exothermic, thus favored by a decrease in temperature
Reactions that break carbon-heteroatom bonds (HDS, HDN, HDM) can be complete under appropriate conditions
Olefin hydrogenation, though reversible, can also be complete under appropriate conditions
Aromatic saturation is reversible and can reach thermodynamic equilibrium
Rise in temperature beyond certain point leads to dehydrogenation rate surpassing hydrogenation rate – increase in aromatic concentration
Limiting temperature can be shifted to higher level by increasing H2 partial pressure

46. VISCOSITY – VI RELATIONSHIP
Aromatics L
Viscosity
Naphthene U
0 VI
Sample H
Paraffin
Viscosity
100 VI
Temperature
Temperature

47. HydroTreatment Operating Parameters Temperature
Temperature Limit for Hydrogenation of Aromatics
Monoaromatics
Di aromatics
Poly Aromatics
% aromatics in HDT product
250
300
350
400
Temperature (°C)
(Gas oil – on NiMo/alumina, PH2=60bar)

48. HydroTreatment Operating Parameters Temperature
Reactor inlet temp. T
Reactor temperature control: Factors:
Furnace outlet / Reactor inlet temperature
Bed delta T
Weighted Average Bed Temperature (WABT / WART)
Inter-bed quench T
Bed
del T T T
Interbed Quench
Rx Heater o/l temp
Fuel
Reactor feed
Reactor product
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49. HydroTreatment Operating Parameters Temperature
Reactor temperature control
Weighted Average Bed Temperature (WABT / WART)
Convenient single point target parameter
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50. HydroTreatment Operating Parameters Temperature
Reactor temperature control
WABT / WART controlled by simultaneous control of
Reactor inlet temperature
Individual bed inlet temperature by regulation of inter bed quench
Additional guidelines:
Under normal steady operations, keep the reactor bed outlet temperatures equal for all beds to get better catalyst life.
This may require different inlet temperature for different beds; Greater exothermicity in inlet bed – hence lower inlet temp for that bed.
Max. allowable delta T across bed specified by designer, normally not more than 20°C
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51. HydroTreatment Operating Parameters Catalyst Ageing
Catalyst deactivation / aging:
SOR – Start of run &
EOR – End of run temperatures are specified by tech. licensor / catalyst vendor.
Graphical monitoring of progress of reactor temperature on daily basis required to estimate extent of aging of catalyst
Actual operating temperatures are normalized for feed quality, t’put and product quality variations and plotted against time
Useful for predicting regeneration or catalyst replacement requirement; to know about sudden loss of activity due to process upset
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52. HydroTreatment Operating Parameters ReCycle Gas rate
Expressed as ratio of Normal cubic meters of hydrogen recycled (excluding quench) to volumetric flow rate of feed in cubic meter at 15°C
Significance:
Maintains adequate H2 partial pressure
Generates turbulence required for proper contacting of feed with catalyst and for better heat transfer in exchangers and heaters
Absorbs reaction heat from exothermic rxns; moderates delta T across cat. bed. Gives better cycle life of catalyst
Requirement higher for heavier feeds
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53. HydroTreatment :Other Operating Parameters
Wash water injection
H2S & NH3 generated from HDT rxn react to form NH4SH type salts which get deposited in cold parts of recycle loop, especially air cooler tubes
To be washed with water injected at air cooler inlet
Wash water injection at least 5 wt % of feed and ammonium salt conc. In HP separator boot water not to exceed 4% from corrosion consideration
Amine absorption
Steady amine flow rate and concentration to be maintained for effective control over recycle gas H2S content
Lower amine temp favors better H2S absorption, but may also cause hydrocarbon condensation – which leads to foaming in absorber
Optimum amine supply temperature to absorber column = 10°C less than Gas inlet temp.
Periodic skimming of accumulated oil in absorber bottom to be done to prevent foaming. Foaming in absorber is indicated by sudden fluctuation in column pressure drop
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54. HydroTreatment :Quality Parameters
Product compositional characteristics:
Sulfur content
Nitrogen content Feed to HDW
Metal content
Aromatics content
Other characteristics
CCR
Viscosity Index of finished Lube Base Oil
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55. Igniting Minds... Energizing Lives…
CIDW unit, The process
Hydro treatment of feed
De-Waxing
Hydro finishing
Recovery
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56. Hydro treatment of feed
Purification of Feed
Removal of S, N
S + H2  H2S + Q
N H2  2 NH3 + Q
S, N are poison to De-Waxing Catalyst
Side Reactions:
Cracking
Saturation of Unsaturates
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57. Hydro treatment of feed
Feed + H2 S, N free feed
+ H2 + HC H2S + NH3
R 01
Exothermic reaction
High Temperature,
High Pressure
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58. Hydro treatment Reactor (R 01)
Three catalyst beds
Total catalyst Volume m3
EM-7420 Ni-Mo Hydrogenation Catalyst
Operating Variables:
Temperature
Hydrogen circulation and partial pressure
Space velocity
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59. Hydro treatment Reactor (R 01)
Operating Conditions
ATTRIBUTE
100 N
150 N
500 N
500 N w/ 500 SW
500 SW
150 BS
HDT Temp, in/out (deg C)
SOR
EOR
302/ /386
302/ /382
302/ /387
302/ /384
302/ /384
302/ /391
*HDT Pres, (kg/cm2 -A)
Inlet
Outlet
143.8
138.5
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60. How to get rid of H2S, NH3?
H2S absorbed in Lean diethyl amine solution
C 02 Amine absorption Column
NH3 absorbed in water
C 03 Wash Water scrubber
Recycle Treated Gas back to the system using Recycle compressors

61. De-Waxing Conversion of N paraffins to Iso Paraffins
N paraffins Waxy in Nature
Iso Paraffins Non – Waxy
Isomerization
Side Raections
Cracking
Saturation of unsaturates

62. De-Waxing Low pour point product + H2 + HC
Clean feed Ex R 01 + Treated H2
Highly Exothermic Reactions
High Temperature
High Pressure

63. De-Waxing Reactor, R 02 Three catalyst beds
Total catalyst volume = 40.8 m3
Bed 1 – EM Pt/Pd Hydrogenation catalyst for HDS, HDN and aromatic saturation.
Bed 2&3 - EM-7300 Pt. Isomerisation Catalyst
Operating Variables:
Temperature
Hydrogen circulation and partial pressure
Space velocity

64. Igniting Minds... Energizing Lives…
De-Waxing Reactor, R 02
Operating Conditions
ATTRIBUTE
100 N
150 N
500 N
500 N w/ 500 SW
500 SW
150 BS
MSDW Temp, in/out (deg C)
SOR
EOR
304/ /382
304/ /381
304/ /385
304/ /386
304/ /390
304/ /388
*MSDW Pres, (kg/cm2 -A)
Inlet
Outlet
126.8
120.5
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65. Igniting Minds... Energizing Lives…
Hydrofinishing
Product stabilization through saturation of poly nuclear aromatics
Improvement in Color
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66. Hydrofinishing Reactor, R 03
Low pour point product + H2 + HC
Hydro finished product + H2 + HC
High Temperature
High Pressure
Mild Exothermic

67. Hydrofinishing Reactor, R 03
Two catalyst Beds
Total catalyst volume = 27.2 m3
EM Pt/Pd Aromatic saturation
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68. Hydrofinishing Reactor, R 03
Operating Conditions
ATTRIBUTE
100 N
150 N
500 N
500 N w/ 500 SW
500 SW
150 BS
HDF Temp, in/out (deg C)
SOR
EOR
247/ /291
*HDF Pres, (kg/cm2 -A)
Inlet
Outlet
118.3
113.0
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69. Control Of Reaction Exotherm
Quench --Cold recycle hydrogen flow to all reactor beds

70. CATALYTIC DEWAXING:GENERAL FLOWSHEET
Recycle
Hydrotreating
CDW
Purge
Hydrofinishing
Feed
Separator
Make Up hydrogen
Naphtha
Hydrotreater Effluent Scrubbing Section
Diesel
Product Fractionation Section
Group III LOBS Product
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71. HALDIA CDWU High Pr. Feed/Reactor Section
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72. HALDIA CDWU Low Pressure Recovery Section
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73. HALDIA CDWU Operating Parameters
WART, HDT, degC
WART, HDW, deg C
WART, HDF, deg C
LHSV, sec-1
1-1.5
Operating pr, kg/cm2g
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74. YIELD PATTERN OF CATALYTIC DEWAXING UNIT HALDIA
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75. Lube Base Oil Product Qualities
Grade
KV (cSt)
VI (min.)
Pour Point (max) GR I
150N
28-32 (40oC)
100 -9
500N
10 (100oC) 95 -6 HN
13.5 (100oC) 92 -3 BN
32 (100oC) II
70N
(40oC)
-21
(40oC)
105
-15
(40oC)
95 (105)
150BS
30 (100oC)

76. GROUP – I / GROUP – II LOBS
Group I grade LOBS
Group II grade LOBS

78. NEW GENERATION LUBRUCANT WILL REQUIRE
LUBRICANT
PERFORMANCE REQUIRED
BASE STOCK PROPERTY NEEDED
ENGINE OILS
LOW EMMISSIONS,
LOW OIL CONSUMPTION
FUEL ECONOMY
EXTENDED DRAIN
LOW VOLATILITY AT LOW VISCOSITY
LOW VISCOSITY & HIGH VISCOSITY INDEX
OXIDATION STABILITY
GEAR OILS
FILL FOR LIFE
HIGH VISCOSITY INDEX(GR-III)
TRANSMISSION FLUID
EXCELLENT FLUIDITY
LOW VISCOSITY, LOW VOLATILITY

79. THANK YOU

80. BASE OIL TRENDS Lesser availability of lube bearing crude
Market share (%) s
2000
API Gr I
75-85
50-60
API Gr II
10-15
30-40
Others
1-2
5-10
Lesser availability of lube bearing crude
Better fuel economy, improved performance and extended drainage
Impact on environment

81. ADDITIVES Required to impart or enhance desired properties of oils.
Dispersants
Detergents
Oxidation inhibitors
Rust and corrosion inhibitors
Viscosity Index improvers
Pour Point depressants
Foam Inhibitors
Anti-wear Agents/Friction modifiers

82. LOBS Manufacture by HydroProcessing Alternative Route-I
Pour Point
VI, CCR
KV,
Flash Point
Colour &
Stability
Gas
Naphtha
Vacuum Distillates
VGO
Waxy Raffinate
De-waxed oils
Kero
Catalytic Dewaxing Unit
Vacuum distillation
HydroFinishing Unit
Diesel
Lube HydroTreater
Gr-II LOBS
70N/100N
150N
Propane
De-Asphalting
RCO
500N
150BS

83. LOBS Manufacture by HydroProcessing Alternative Route-II
Pour Point
VI, CCR
KV,
Flash Point
Colour &
Stability
Gas
Naphtha
Vacuum Distillates
Vacuum Distilled HydroCrackate Residue
VGO
De-waxed oils
Kero
Catalytic Dewaxing Unit
Vacuum distillation
HydroFinishing Unit
Diesel
Hydro Cracker
Gr-II LOBS
70N/100N
150N
Propane
De-Asphalting
RCO
500N
150BS

84. FUNCTIONS OF LUBRICATING OIL
REDUCE FRICTION &WEAR
PREVENT SCUFFING & SEIZURE OF MOVING PARTS.
REMOVE HEAT FROM CONTACT SURFACE.
PREVENT RUST & CORROSION.
PREVENT EXCESSIVE DEPOSITS & SLUDGE FORMATION
DISPERSION OF GENERATED CONTAMINANTS
MAINTENANCE OF WATER SEPARABILITY & EMULSIBILITY
MAINTENANCE OF SEALING IN CRITICAL PARTS.
MAINTENANCE OF RESISTANCE TO DEGRADATION IN PRESENCE OF OXYGEN & CATALYTIC MATERIALS.
Igniting Minds... Energizing Lives…
Haldia Refinery

85. Vacuum Distillation Unit PFD (preheat and product cooling section )
B-1
E-121
E-1A
E-1B
E-1C
E-1D
E-2A
E-2B
E-2C
E-123
E-127
E-14A/B
E-6A
E-6B
E-6C
E-4B
E-4A
E-122A/B
E-7
E-9
E-11
RCO Ex tanks
LO Ex P-5/5R
GO Ex P-3/3R
SO Ex P-7/7R
PA Ex P-6/6R
IO Ex P-12/12R
HO Ex P-8/7R
SR Ex P-10/10R
H-1A
H-1B
DM water
To VB steam
header CW
To TK-761
GO to R/D
GO to top reflux
RCO to P-113/113R suction
SO to R/D
E-10 TW
E-125A/B
IO to R/D
HO to R/D
SR to R/D
E-126A/B
E-124A/B
Pump Around To # 18 of C-1
IO to VBU
FC-20
FC-21
LO R/D
To Tar
To VBU
FC-15
FC-19
FC-23A
FC-22
FC-23
To HSD
FC-25
FC-24
FC-27
FC-26
To R/D
FC-12
FC-28
LC-02
TC-06
Vac slop to PDA
Vac slop Ex P-9/9R
To PDA
Bot quench
Igniting Minds... Energizing Lives…
Haldia Refinery

86. Vacuum Distillation Unit PFD (furnace and fractionator circuit)
P-113/113R
SR to E-11
RCO ex F-1/F-2 CW
To Ejectors
VS STEAM
GO as reflux
ex E-2A/B/C #1 #4 #5 #8
#12
#16
#19
#22
#26
C-1
F-2
Burners
Fuel gas
IFO supply
IFO return
Atomising steam
RCO Ex E-11
P-10/10R
P-8/7R
P-12/12R
P-5/5R
P-7/7R
HO draw
IO draw
LO draw
PA draw
SO draw
GO draw
SR draw
P-9/9R
Vac slop to E-9
Over Flash
HO Ex P-8/7R
as Demister Wash
Bot Quench Ex H-1A/B
Furnace recycle Ex p-9/9r
VB steam
VS steam
Turbulising
steam
Turbulising steam
Combustion air
Ex APH
P-6/6R
E-6A/B/C
P-3/3R
E-128A/B
GO to E-1A/B/C/D
SO toE-123
LO to E-121
IO to E-7
HO to E-9
LC-101
LC-03
FC-11
LC-04
LC-05
FC-10B
FC-13
FC-12
FC-10A
FC-4
FC-5
FC-8
FC-9
FC-102
PC-06
HV-01
DPC-03
FC-209
FC-216
FC-217
FC-201
FC-202
C-105
C-2
C-3
C-4
Igniting Minds... Energizing Lives…
Haldia Refinery

87. Vacuum Distillation Unit PFD Vacuum System
E-128A CW
#19
#22
#26
E-128B
E-129
E-130
31C-1
Cooling Water Inlet Header
Cooling Water
Return Header
VM Steam to Ejectors
PEJ
SEJ
B-2
B-7
seal pot
Vent
oil
water
Barometric legs
P-101/101R
P-102/102R
B-3
coaleser
Hot well gas oil to HSD pool
Hot well water to OWS/ Desalter
Hot well
PC-05
PC-121
VB steam
DM water
P-114A/B/C
E-116A/B/C
E-124A/B/C
E-126A/B
E-125A/B
E-10
Tempered water circuit
B-105 SR HO IO
Vac
Slop
Tempered water

88. FILTRATION & CHILLING SECTION OF SOLVENT DEWAXING UNIT
To vacuum compressor
suction via B-12A/B
Feed to DP Chiller
Train series -1
Feed to 6 series of
parallel DP Chiller
Trains.
Feed Ex parallel
DP chiller
series 2-7
Sec Dil to DP chiller
Filtrate to DP Exchangers
of Chiller series 2-7
Filtrate Ex DP Exchangers
SDA Dosing
Wax injection
P-1/I
P-1/II
B-1
B-2
S-1
B-3a
P-3/I
VB Steam
Secondary Dilution solvent
Tertiary
Dil solvent
Cold wash
solvent
Hot wash
Feed Ex tanks M
Solvent Ex B-8 / B-9
E-1/I
E-1/II
E-2/I
E-2/II
LR-1A
LR-1B
LA-1B
LA-1A
LA-1C
E-4A
E-4B
E-4C
E-4D
E-3A/B
E-3C
E-18
To S-2
to S-11
From S-2
Wax-mix Ex
P-3/II-XI
P-2/2R
E-31
VM steam
B-7
Wax-mix to
solvent recovery
P-8/8R
To B-11
Purging
Blowing
Seal pot
B-20A
Filtrate
VB stm CW
DWO-Mix to solvent recovery
P-4/5/5R
Primary Dilution solvent
K-3A/B/C
B-24
B-25
B-3.11
B-3.8
E-3.6A/B/C
E-3.7A/B/C
E-3.9
E-3.12
Sub cooler
B-3.10
Liquid Ammonia
B-26
To/From storage
Drain
from B-3.8
To Aux comp suction/
From Discharge
Drain from chillers
and E-4A-D
from storage
To Aux comp
suction
B-15
From Aux comp
discharge
Ammonia vapors
to consumers
Vapour Ammonia

89. Igniting Minds... Energizing Lives…
FURFURAL EXTRACTION UNIT Extractor Section
PAGE:1 of 3
Steam
To E-13b
or E-8
Atm
LC-01
E-2
J-1 CW #1
E-1
E-2A/B
Feed to Unit
C-1 CW
VM steam
Ex P-8/8R
or P-9/9R
VS steam
33P-1/1R
33P-2/2R
To E-4A/B O/L
Raffinate Mix
To P-3/2R via B-1
Extract Mix to C-5
Via E-10A
E-15
E-3
E-9 CW
C-2 CW #3
TC-12
Ex P-12B
E-8
B-11
P-11/11R CW
P-6/6R
E-10B
Furfural Ex C-9 Bot
Igniting Minds... Energizing Lives…
Haldia Refinery

90. FURFURAL EXTRACTION UNIT (U-33) Solvent Drying section
PAGE:3 of 3
P-10/10R
VB steam
P-12A/10R
P-4/4R
P-11/11R
B-3
B-2
B-4
E-5
E-6
E-14 CW
C-9
C-10
To C-2
Furfural To C-2
Ex C-5 liquid
Ex C-6 liquid
Ex C-5 Vap
Ex C-6 Vap
#13 #7 #6 #1
#18
Ex C-3
Ex C-7
Ex C-4
Ex C-8
steam
To seal pot
To ETP
Igniting Minds... Energizing Lives…
Haldia Refinery

91. NMP EXTRACTION UNIT (U-38) Igniting Minds... Energizing Lives…
Solvent Ex P-5A/B
NMP EXTRACTION UNIT (U-38)
Extraction and Raffinate-Mix Section
PAGE:1 of 2
Feed to Unit
Ex Tanks
E-1A/B
E-1C
LC-1101
C-2 CW
VM steam
Extract R/D
Ex P-9A/B
44P-101A/B
38P-2A/B
P-10A/B
E-17
V-7
E-7A/B/C
E-18
V-6
P-3A/B
E-3A/B
C-1
#10 #1
TC-1102
FC-1101
TC-1202
FC-1202
FC-1201
TC-1201
To V-14
PC-1210
Reflux to C-5/6/7/8/9
FC-1203 IG
PC-1201
PC-1209
TC-1101
E-2 A/B
LP steam
V-8
Ex C-10 Top
Water injection
Ex v-4/ v-10
Inert gas
V-1
i.e C-10 Bottom
F-2
P-4A/B
P-6A/B
E-4
E-24
E-6
To V-5
E-5A-D
MP steam
C-3
C-4
E-13
To V-9
Raffinate R/D
FC-1401B
#20
#16
Reflux Ex P-4A/B
LC 1601
FC-1603
# 4
OWS #7
FC-1401A
E -14
HP Steam
Extract-Mix To C-5
Igniting Minds... Energizing Lives…
Haldia Refinery

92. NMP EXTRACTION UNIT (U-38) Igniting Minds... Energizing Lives…
Extract -Mix and Solvent Drying Section
C-8
C-9
F-1
P-9A/B
P-8A/B
VS steam CW TW
E-11
Deareator feed Ex 44P-101
E-8
E-9A/B
Extract R/D
C-5
C-6
C-7
E-20
P-18A/B
E-1A/B E-
To C-1
Extract
recycle
P-11A/B
E-23
A/B/C
P-12A/B
V-9
J-002
V-5
PAGE:2 of 2
P-7A/B
V-4
E-15
C-10
#27
#10 #7 #5 #1
38PC-1806
Ex C-3 Top
Ex C-4 Top
J-001 A B
E-22A
E-22B
E-21A
E-21B
MP Steam
V-10
P-15A/B
Water Injection to E-17 / V-4
P-13A/B
E-16
HP Steam
T-2A/B
Slop Tks
To Solvent Manifold
To Slop Manifold
V-14
CBD
P-17A/B
P-20
P-5A/B
#20 #4
HP steam
Extract-MixFrom C-2 Bot
To V-8
PC-1805
FC-1801
T-1A/B
Solv Tks
P-21A/B
E-12
Igniting Minds... Energizing Lives…
Haldia Refinery

93. SOLVENT RECOVERY SECTION OF SOLVENT DE-WAXING UNIT
E-5A/B
E-7A/B/C/D
DWO-Mix
Ex E-3C
Wax-Mix
Ex P-8/R/RR
C-5
C-1
C-2
C-3
C-4
C-10
#30
#12 #7 #1
C-8
B-11
E-15A/B/D
E-17A/C
VS steam
E-30
VB steam
C-6
C-7
C-105
E-12
E-9
E-14
E-111
E-17B
E-16
E-6 CW
DWO R/D
Sl Wax to FCCU
VM steam
E-17D
E-15C
B-8
B-9
P-4/5/5R
Dry solvent
to re-use
P-11/11R
P-20A/B
P-21A/B
P-7/7R
P-109/109R
P-9/9R
P-10/10R
E-8A/B/C/D
E-13
P-6/6R
VB Stm
IFO
Slop
TK 763
TK 869/871
Foots oil Ex C-104 bot

94. Igniting Minds... Energizing Lives…
B-14
34-T-1
B-16a
B-16b
inert gas to blanketing header for
vessel blanketing in SDU
B-12a
B-12b
B-2
filtrate vessel
knock out
drums
B-13
K-1a
K-1b
E-19
E-20a
E-20b
Liq NH3 cw M
I G to Filters Hood
I G to B-1
I G to Filters Blowing
I G to FEU,SDU for purging
Separator
Funnel
DPIC-01
DICV-04-2
DICV-04-1
To B-2
To B-5
PSA N2
storage
vessel
N2 Ex PSA
INERT GAS GENERATION AND DISTRIBUTION SYSTEM IN SOLVENT DE-WAXING UNIT
Igniting Minds... Energizing Lives…
Haldia Refinery

95. PROPANE DE-ASPHALTING UNIT
PAGE:1 of 1
Feed to Unit
Ex P-1/1R/101
C-1A/B/C
&
C-101
F-1
E-112A/B
C-110
C-108
E-121A/B T M
MX-01
MX-3/4
MX-02 FC
E-10
VB Steam
P-5
P-110A-F
B-1/2
Propane vessel
K-1/1R
B-3
C-7
C-6
C-4
C-5
C-2
P-3/3R
P-103A/B
DAO R/d
P-4/4R
E-6A/A1-I/I1
E106A-C
E-107
E-114A-C TW
E-119
VM Steam
E - 8
E - 4 CW
E-120A
CW or
ETP Water
Local drain
E-115
To Slop
VS steam
Flare
E-9
E-109
PC-2A
Asphalt
to VBU
Asphalt to TPS
Asphalt to BTU
FC-16
MHP Steam
P-102A/B/C
E-116
E-117 PC LC
Propane Solvent
E-122
E-5A/B
Igniting Minds... Energizing Lives…
Haldia Refinery

96. PFD of Hydrofinishing Unit
B-10
Feed
P-1A/B
E-6A/B
Ex C-3 bot R/D
R/D cooler
E-5
FC-03
TC-03
TC-01
E-1A/B/C
F-1
R-1
B-2
B-3
C-1
E-2 CW
B-9
LC-02
LC-05
LC-03
PC-03
Off gas to fuel gas
K-2A/B/C
Rich amine
P-6A/B/106
To B-4
Page 1 of 2
Recycle gas H2
Make up
gas H2
K-1A/B
B-1
E-8
To fuel gas
PC-01
PFD of Hydrofinishing Unit
Lean amine

97. FURFURAL EXTRACTION UNIT (U-33) Solvent Recovery
PAGE:2 of 3
VS steam
C-3
C-4
C-5
C-6
C-7
C-8
F-1
F-2
P-3/2R
P-5/5R
P-9/9R
P-7/7R
B-1
E-4A/B
E-5
E-6A/B
E-7 CW
DM water
Steam to F-1/F-2
E-10A
E-11
E-12
To C-9
Extract R/D
To B-2
To B-3
Raffinate R/D
Raff mix
Ex C-2 top
Inert gas
Extract Mix
Ex C-2 bot
Via E-9
PC-3
Igniting Minds... Energizing Lives…
Haldia Refinery

98. Lube Hydrofinishing unit
C-2
C-3
P-2A/B
E-6A/B
E-5
Feed Ex P-1A/B
To E-1A/B/C s/s CW
Stripping steam
E-4
E-3
VM steam
PC-04
To fuel gas
LC-06
LC-08
LC-11
LC-18
To drain
drain to Sour Water
Product R/D
LC-09
Page 2 of 2
To F-1
#15 #1
From B-2 / B-3
bottom
Lube Hydrofinishing unit