Optimization study in hydrocracker unit using simulation model. The choice of the process configuration is tied to the catalyst system. In petrochemistry, petroleum geology and organic chemistry, cracking is the process whereby complex organic molecules such as kerogens or longchain hydrocarbons are broken down into simpler. This configuration uses only one reactor and any uncracked residual hydrocarbon oil from the bottom of the reaction product fractionation tower is not recycled for further cracking. It is an option to let the uco recycle pass a hpna trim unit for removal and management of hpna compounds before it is recycled back to the reactor. Volume and annual % demand growth by region, 2008 2030. The fcc unit converts vacuum gasoil into lpg, gasoline and diesel. A hydrocracking unit, or hydrocracker, takes gas oil, which is heavier and has a higher. The major secondary processing units of the refinery include catalytic reforming unit, once through hydrocracker unit, resid fluidised catalytic cracking unit, visbreaker unit, bitumen blowing unit, sulphur block and associated auxiliary facilities. Fluid catalytic cracking and hydro cracking nptelhrd.
Hydrocracking plant passes the heavy oil onto the catalyst under high temperature. The unit can consist of one or two reactors with either one or multiple catalysts. In addition to crude and vacuum distillation units, the major refining units are catalytic reforming unit, once through hydrocracker unit, resid fluidised catalytic cracking unit, visbreaker unit, delayed coking unit, bitumen blowing unit, hydrogen generation unit, sulphur block and associated auxiliary facilities. In our once through hydrocracker unit, the recycle gas. Oncethrough hydrocracker in combination of rfcc would enable higher propylene rich. The hydrocracker unit will be revamped to once through operation to produce feedstock for base oil. In our once through hydrocracker unit, the recycle gas compressor is surging from 100% opening of the antisurge valve to 0% without any change in process parameters.
For this case study, a hydrocracker unit model onestage and once through was prepared and validated with site data, using a commercial simulation program. Indian oil corporation limited barauni, refinery along with. Speciality hydroprocessing celestia exxonmobil chemical. Composite work for 2 x 80tpd sulphur recovery unit sru of once through hydrocracker project at haldia. Once through hydrocracker unit hck ohcu is designed to process 240 m3hr capacity, licensed by ms chevron lummus global ltd,usa. The hydrocracking reactor effluent goes through gasliquid separation and then to the fractionator. Hydrocracker units can be operated in the following possible modes. Some hydrocrackers are singlestage units with just one reactor that is usually. In contrast to fixedbed hydrocrackers, ebullated bed ebed units can process. Hydrocracker units contain at least three of the six corrosion causing substances. In single stage scheme, the uncovered material from fractionator.
Hydrocracking plant passes the heavy oil onto the catalyst under hightemperature. The feed is first hydrotreated and the reactor effluent goes through gasliquid separation. The feedstock is not completely converted to lighter products. Indianoil commissions oncethrough hydrocracker unit at. In a refinery, the hydrocracker upgrades vgo through cracking while injecting.
Corrosion due to sour water can be expected in reactor effluent and light ends sections of hydrocrackers. The products from hydrocracking unit will also vary in boiling range depending upon cracking severity. Indian staterun bharat petroleum corp ltds refinery at kochi will undergo a shutdown for 15 days to. A stacked load of celestia and nebula catalysts was loaded into the pretreat section of a oncethrough heavy feed hydrocracker, processing a challenging blend of high endpoint virgin and coker vacuum gas. Delayed coker unit, ranked second on margins, selected for residue upgradation.
Once through hydrocracker revamp tia digital refining. Optimising hydrogen production and use h ydrogen plays a critical role in the production of clean fuels, and its. Zero capex option is defined as using no capital expenditures to increase the. Mechanicalepc contractor for total lumpsum turnkey projects. This configuration uses only one reactor and any uncracked residual hydrocarbon oil from the bottom of the reaction product fractionation tower is not recycled for. Uop hydrocracking technologylong history, sustained innovation. Epcc 06 package for new ohcu and fgtu for barauni tender.
The feed is first hydrotreated and the reactor effluent goes through. After this step, optimization studies were performed for energy efficiency, column product yields and product specifications. In our once through hydrocracker, the fractionator feed furnace has options for both fuel oil and fuel gas firing. Hydrocracking is a catalytic chemical process used in petroleum refineries for converting. This type of hydrocracker usually requires the least capital investment. Projects mechanicalepc contractor for total lumpsum. A simple hydrocracker looks, for those that do not have one in their refinery, just like a hydrotreater. This configuration uses only one reactor and any uncracked residual hydrocarbon oil from the bottom of the reaction product fractionation distillation tower is not recycled for further cracking. A singlestage once through ssot unit resembles the first stage of the twostage plant. Epcc package epcc06 for new once through hydrocracker unit ohcu and fuel gas treatement unit fgtu and allied facilities for barauni refinery capacity expansion to 9. Clean, green, hydrocracking machine technology marketing. Hydrocracking is an important source of diesel and jet fuel today in.
In single stage scheme, the uncovered material from fractionator bottom is recycled to first reactor along with fresh feed. Some days back inspection department reported a much higher skin temperature in the radiation section of the furnace. For single stage hydrocracking, either the feedstock must first be hydrotreated to remove ammonia and hydrogen sulfide or. In the twostage scheme, the unconverted material is routed separately to another. Am1525 new hydrocracking developments demonstrate lower.
Indianoil commissions oncethrough hydrocracker unit at haldia. Hydrocracking, processing heavy feedstocks to maximize. For this case study, a hydrocracker unit model onestage and oncethrough was prepared and validated with site data, using a commercial simulation program. A twostage hydrocracker with intermediate distillation represents the most common process configuration for maximizing middle distillates. Hydrocracker unit how is hydrocracker unit abbreviated. Typical process flow of hydrocracking singlestage onethrough system.
It is an option to let the uco recycle pass a hpna trim unit for. To evaluate potential network improvements, a detailed refinerywide model of the hydrogen network should be employed. In our once through hydrocracker, the fractionator feed. It was also observed that just prior to surging the total flow at the inlet of the rgc was also increasing. Hydrocracking is widely used in petroleum refining to convert heavy oil fractions which may include residues into lower molecular weight hydrocarbons through cc bond breaking. Hydrocracking units can be configured in a number of ways.
Mechanicalepc contractor for total lumpsum turnkey. Corrosion due to hydrogen sulfide can be expected to occur in hydrocracker effluent streams. The turnaround is set to take place between october and december, starting with the fluid catalytic cracking unit. This is in contrast to the fcc, which uses the same feed vgo but produces more and betterquality gasoline.
The product is fractionated into light ends, naphtha, kerosene, diesel, and uco. The products from hydrocracking unit will also vary in boiling range depending upon cracking severity and mode of operation once. Routing light naphtha from once through hydrocracker to hydrogen generation unit mei 2011 okt 2011 a detailed feasibility report was prepared to use the light naphtha from hydrocracker as a feed. Isocracking hydrocracker designs include singlestage once through, singlestage recycle and twostage recycle processes. Hydrocarbonengineering chevron technology marketing.
The maintenance for the oncethrough hydrocracker fractionator will commence around november. Once through hydrocracking is without liquid recycling. Murugan subbiah hydrocracker operation shift supervisor. Fluid catalytic cracking produces a high yield of petrol and lpg, while hydrocracking is a major. A hydrocracking unit, or hydrocracker, takes gas oil, which is heavier and has a higher boiling range than distillate fuel oil, and cracks the heavy molecules into distillate and gasoline in the presence of hydrogen and a catalyst. Hydrocracking is a refining technology in which the outcome is the conversion of a variety of. Mechanical works for compressor station at kailaras. Staterun refiner indian oil corporation has scheduled a maintenance program for the fluid catalytic cracking unit, continuous catalytic reforming unit and oncethrough hydrocracker. In march 2004, cpcl commissioned a singlestage once through ssot hydrocracker unit using clgs isocracking process with an installed capacity of 37611. Currently due to some problem in the electrical heater in the fuel oil circuit we are using only fuel gas. The maintenance for the once through hydrocracker fractionator will commence around november. Indian staterun bharat petroleum corp ltds refinery at kochi will undergo a shutdown for 15 days to replace a catalyst in a hydrotreater during the fourth quarter of 2019.
A hydrocracking unit takes heavy gas oil from the atmospheric tower, the vacuum. Clgs isocracking technology is the most flexible upgrade path to lighter productsa path that can help you reach a balance between stringent product specifications, product yield, cycle run length, capital investment and operating costs. Orpic completes installation of omans first hydrocracker. As total conversion is not required, oncethrough hydrocracking can be carried. Feed endpoints are critical to control in order to minimize contaminant level and catalyst deactivation. Figure 1 shows major equipment of a singlestage oncethrough ssot hydrocracker consisting of a. Indianoil commissions once through hydrocracker unit at haldia refinery and expands its capacity to 7. A 70 % conversion hydrocracker unit is considered in the configuration. Ohcu is for partial conversion on feed into products which is a extremely versatile catalytic process, processing heavy feed stock in the presence of hydrogen and catalyst yielding lighter products and preparing feed for fccu. Composite work for 2 x 80tpd sulphur recovery unit sru of once through hydrocracker project at haldia refinery on single point responsibility basis.
This yields a high volume of highquality diesel and kerosene product. The unconverted bottoms can go to an fcc unit, a lube plant, or fueloil. The hydrocracker upgrades lowquality heavy gas oils from the atmospheric or vacuum distillation tower, the fluid. Currently due to some problem in the electrical heater in the fuel oil. Figure 1 shows major equipment of a singlestage once through ssot hydrocracker consisting of a high pressure section in orange and a low pressure section in blue. Indianoil commissions oncethrough hydrocracker unit at haldia refinery and expands its capacity to 7. Composite work for 2 x 80tpd sulphur recovery unit sru of once through hydrocracker project. In march 2004, cpcl commissioned a singlestage once through ssot hydrocracker unit using clgs isocracking process with an installed capacity of 37611 bd. Epcc package epcc06 for new once through hydrocracker unit ohcu and fuel gas treatement unit fgtu and allied facilities for barauni. To enhance the distillate yield of the refinery and improve the bottomline, besides producing euroiv grade diesel and superior quality products, indianoils haldia refinery has commissioned the prestigious once through hydrocracker unit ohcu project. Description of hydrocracking process hydroprocessing for. Clgs isocracking technology is the most flexible upgrade path to lighter productsa path that can help you reach a balance between stringent product specifications, product yield, cycle run length.
Once through hydrocracker in combination of rfcc would enable higher propylene rich lpg yield, which is the feedstock for downstream petrochemical unit. Part 3 fluidised catalytic cracking unit and hydrocracker duration. In a refinery, the hydrocracker upgrades vgo through cracking while injecting hydrogen. To enhance the distillate yield of the refinery and improve the bottomline, besides producing euroiv grade diesel and superior quality products, indianoils haldia refinery has commissioned the.
A singlestage oncethrough ssot unit resembles the first stage of the twostage plant. The consequence of a failure due to this tower would be a total hydrocracker unit shutdown at 24,000 bpd production loss. Comparison of hydrocracker flow schemes single stage once through. More loosely, outside the field of petroleum chemistry, the term cracking is used to describe any type of splitting of molecules under the influence of heat, catalysts and solvents, such as in processes of destructive distillation or pyrolysis. These operation modes are shown in figures 31 and 32. Indian oil corporation limited barauni, refinery along. Sanjay pandey senior instrumentation engineer petrofac. Catalysts used for hydrocracking are bifunctional, as they comprise a hydrogenationdehydrogenation function provided by metals, and an acidic function given by the. Orpic installs omanaacaos 1st hydrocracker reactor. A hydrocracking unit, or hydrocracker, takes gas oil, which is heavier and has a higher boiling range than distillate fuel oil, and cracks the heavy. The commercial unit proceeded with catalyst system b for maximizing distillate yield with over 19 months of satisfactory operation. Chevron lummus global clg, a joint venture between chevron usa inc. The hydrocracker is a highpressure, moderate temperature conversion unit. Flawless flow feedstock for the new facility will be provided by the lowsulphur diesel hydrocracker unit commissioned at the bapco refinery in 2007.
Iranian isomax unit phase 3 new slurry hydrocracker. Hydrocracking, processing heavy feedstocks to maximize high. Once through hydrocracker in once through operation, there is no recycle and fractionation bottom is taken as product fcc feed. Tables 11, 12 and summarize the group discussion results and ram and economic analysis summaries. Single stage once through ssotand twostage to produce transportation fuels, middle distillates, and naphtha4. In addition to crude and vacuum distillation units, the major refining units are catalytic reforming unit, oncethrough hydrocracker unit, resid fluidised catalytic cracking unit, visbreaker unit. Flawless flow feedstock for the new facility will be provided by the lowsulphur diesel hydrocracker. Optimising middle distillate production in a hydrocracker. One of the critical features of this model as opposed to a spreadsheet model is that it simulates the nonlinear relationships.