CNERGYICO PK LTD

INTERNSHIP REPORT

SUBMITTED BY: UZAIR AHMED

UNIVERSITY: MEHRAN UNIVERSITY OF ENGINEERING AND

TECHNOLOGY

DEPARTMENT : CHEMICAL ENGINEERING

SEMESTER: 8TH

SUPERVISOR : SIR NABEEL KHAN

INTERNSHIP DEPARTMENT: TECHNOLOGY

DURATION: 4 WEEKS

FROM: 07 JUNE 2024 TO: 05 JULY 2024

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Acknowledgement:

First of all, I would like to express my gratitude to Almighty Allah to enabling me to complete
this report on “Oil Refinery and Its Unit Operations and Processes”.

Successfully completion of any type of project requires help from a number of persons. I have
also taken help from different people for the preparation of this report. Now, there is a little
effort to show my deep gratitude to that helpful person.

I convey my sincere gratitude to my Internship Supervisor Sir Nabeel Ali Khan, Assistant
Manager in ORC 2, Cnergyico Pk Ltd. Without his kind direction and proper guidance this
study would have been a little success. In every phase of the project his supervision and
guidance shaped this report to be completed perfectly. I would also like to thanks to all the
Other Engineers and Operators which were looking after all the different Units because with
their help I was able to understand and properly integrated the concepts of Refinery and
different Equipments along with their Workings.

Executive Summary:
This Report is about my internship program with Cnergyico Pk Ltd. In this comprehensive
report, I have discussed above every major aspect of the Crude Oil Refinery, which I observed
and perceived during my internship program.

In this report you will find the detail about Crude Oil Refinery from its incorporation to the
current position. Along with its processes, policies and procedures of the Oil Refinery are also
discussed in detail.

During my internship program, I mainly worked in Field Area where the Refinery and it’s
Equipments are located. All the Unit Operations and Their Working is discussed in detail.

As the main purpose of Internship is to learn by working in practical environment and to apply
the knowledge acquired during the studies in a real-world scenario in order to tackle the
problems using the knowledge and skills learned during the academic process.

In the end the learning and experience section consists of all the policies, Processes and
practices which I have undergone through and learned during my internship program.

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 Table of Contents
Acknowledgement: ................................................................................................................................. 2

Executive Summary:................................................................................................................................ 2

Overview Of Cnergyico: ......................................................................................................................... 4

Overview Of Internship Experience: ...................................................................................................... 5

Environmental Health and Safety: .......................................................................................................... 6

Internship Assignment Details: ............................................................................................................... 6

API Gravity: ........................................................................................................................................ 7

Sulphur Content: ................................................................................................................................. 7

TAN Number: ..................................................................................................................................... 8

Unit Operations: ...................................................................................................................................... 9

1. Crude Oil Distillation Unit:......................................................................................................... 9

Desalter: ........................................................................................................................................ 10

Distillation Column:...................................................................................................................... 11

2. Naphtha Hydrotreating Unit: .................................................................................................... 12

PFD Of Naphtha Hydrotreating Unit: ............................................................................................ 13

3. Gas Recovery Unit: ................................................................................................................... 13

PFD Of Gas Recovery Unit: ............................................................................................................ 14

4. Amine Regeneration Unit: ........................................................................................................ 14

PFD Of Amine Recovery Unit: ....................................................................................................... 15

5. Reformer Unit: .......................................................................................................................... 15

Reactor: ......................................................................................................................................... 16

PFD Of Reformer Unit: .................................................................................................................. 16

Conclusion: ........................................................................................................................................... 17

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Overview Of Cnergyico:
Cnergyico Pk Limited (formerly Byco Petroleum Pakistan Limited / Bosicor Pakistan Limited)
is a Pakistani Petroleum company which is a subsidiary of the Mauritian company Cnergyico
Industries Incorporated. It is based in Karachi, Pakistan. It works in oil refining, petroleum
marketing, and petroleum logistics business in Pakistan. It is traded on the Pakistan Stock
Exchange.

The Cnergyico Group was founded by its Founder and first Chairman, Mr. Parvez Abbasi in
the mid-90s with the vision to pioneer change in Pakistan’s energy sector. Cnergyico Pk
Limited was formed in January 1995 as public limited company.

Cnergyico installed its first oil refinery with a 30,000-barrels-a-day capacity at Mouza Kund,
Hub Balochistan, and began commercial production on 1 July 2004.

Cnergyico’s holdings has 982 petrol pumps. Whereas the State-owned Pakistan State Oil Co.
Has 3,500 petrol pumps, Total Parco Pakistan Ltd. Has 800 petrol pumps and Shell Pakistan
Ltd. Has 766 petrol pumps.

Cnergyico is Pakistan’s largest oil refinery by design capacity (155,000 barrels per day) and is
the nation’s only firm having a dedicated Single Point Mooring (SPM). Cnergyico’s SPM the
first and only liquid port in the country. The SPM is Pakistan’s only terminal having a tier 3
oil spill response membership.

Cnergyico refines crude oil into various marketable components including Liquefied Petroleum
Gas, Light Naphtha, Heavy Naphtha, High Octane Blending Component, Motor Gasoline,
Kerosene, Jet Fuels, High Speed Diesel and Furnace Oil. Having operated as a low complexity
refinery since inception, it is upgrading to produce more high value products, with reduced
sulphur content, in diesel and convert furnace oil into gasoline and diesel. Cnergyico’s
marketing network supports retail outlets in more than 100 cities all over Pakistan and is an
emerging player. Cnergyico aims to become the first refinery in Pakistan by upgrading its
facilities to ensure environmental compliance.

Cnergyico Pk Ltd acquiring 57.37 per cent shares of Puma Energy Pakistan and has become
the country’s second-largest fuel retailer.

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Overview Of Internship Experience:
An internship is a professional learning experience that offers meaningful, Practical work
related to a student’s field of study or career Interest. An internship gives a student the
opportunity for career exploration and development, and to learn new skills.

My Internship Experience with Cnergyico and its staff was very great and appreciated. There
are three main reasons for that:

• It was my Fourth Internship Experience but This internship was one of the best
internships I ever did.
• The Company’s Staff was very well behaved, co-operative, skilled and
knowledgeable So it was a memorable experience to work with/under them.
• The Company is the biggest Refinery with one of the most dedicated and talented
Engineers and it was pleasure to work in this friendly, focused and learning
environment.

When I came here for the first time so I was kind of nervous and clueless that how the Refinery
works and how the Experienced Engineers will treat student like me who has yet to learn a
Ocean of Knowledge. But I was very comforted to see their behaviour towards me which
motivated me to learn and grasp as much knowledge as I can and transfer that knowledge to
my fellow bachelors. It was my good luck and I had done a very good decision to come here
as a Internee in my Summer Holidays because for me this Month was very important for my
graduation and my Holidays did not go to waste by coming here.

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Environmental Health and Safety:
On my first day at the refinery for my internship, I was introduced to the essential protocols of
health and safety, which are paramount in such an environment. Here in Cnergyico, The
Implementation of Dupont Process Safety Management, which are 22 implemented elements.
The which session was thorough, highlighting the critical importance of maintaining safety and
discipline near the plant. This foundational briefing emphasized the potential hazards and the
necessary precautions to mitigate risks, ensuring that all personnel, including interns like
myself, contribute to a safe working environment.

Furthermore, I was provided with personal protective equipment (PPE), which included a
coverall, goggles, and a helmet. The experienced staff demonstrated the

correct way to don these protective gears, ensuring maximum safety and comfort.

This hands-on guidance was invaluable, as it instilled confidence in me about how to properly
equip myself to prevent accidents and injuries while on site.

Overall, the introduction to health and safety procedures, along with the provision

and demonstration of PPE, underscored the refinery's commitment to safeguarding

Internship Assignment Details:

Petroleum, also known as crude oil, or simply oil, is a naturally occurring yellowish-black
liquid mixture of mainly hydrocarbons, and is found in geological formations. The name
petroleum covers both naturally occurring unprocessed crude oil and petroleum products that
consist of refined crude oil. A fossil fuel, petroleum is formed when large quantities of dead
organisms, mostly zooplankton and algae, are buried underneath sedimentary rock and
subjected to both prolonged heat and pressure.

Petroleum has mostly been recovered by oil drilling. Drilling is carried out after studies of
structural geology, sedimentary basin analysis, and reservoir characterisation. Recent
developments in technologies have also led to exploitation of other unconventional reserves
such as oil sands and oil shale. Once extracted, oil is refined and separated, most easily by
distillation, into numerous products for direct use or use in manufacturing, such as gasoline
(petrol), diesel and kerosene to asphalt and chemical reagents used to make plastics, pesticides
and pharmaceuticals.

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Pakistan is not a Oil Producing Country because there are not many sites where the Crude Oil
can be extracted so Pakistan Mostly Import Crude Oil from Gulf States and USA. Due to low
number of Refineries in Pakistan all of the crude oil can’t be refined or the Consumption of
Refined petroleum Products in Pakistan is more than the production so that’s why Pakistan also
Import Refined petroleum Products which costs Pakistan a lot.

There are different qualities of Crude Oil which are stated as Heavy and Sour Oil, Light and
Sour Oil, Heavy and Sweet Oil, Light and Sweet Oil.

There are different types of Crudes due to the different percentage of Impurities present in it.
The three main factors to distinguish or characterize a crude are:

➢ API Gravity
➢ Sulphur Content
➢ TAN Number

API Gravity:
The American Petroleum Institute gravity, or API gravity, is a measurement convention
established by the American Petroleum Institute for expressing the relative density of
petroleum liquids to water; the greater the API gravity, the less dense the material. A crude oil
will typically have an API between 15 and 45 degrees. The formula for API gravity is API =
(141.5/SG) -131.5 where SG is the specific gravity of the petroleum liquid being measured. If
the crude is heavy then it will require more refining processes and it will mostly give heavy
products like Diesel, Kerosene and Fuel/Furnace Oil with less percentage of Light Products
like Gasoline, LPG and Fuel Gases. If the crude is light then it will require less Unit Operations
to process and the percentage of Lighter Hydrocarbon products will be more.

Sulphur Content:
Sulphur Content in the Crude Oil is the percentage of Sulphur present in Crude Oil. Now that
Sulphur could be in Compound form Or Elemental form. If the Sulphur present is more than
1% than the crude is called Sour and If the Sulphur is less than 1% than the crude is called
Sweet. The impurities need to be removed before this lower-quality crude can be refined into

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petrol, thereby increasing the cost of processing. This results in a higher-priced gasoline than
that made from sweet crude oil. The majority of the sulphur in crude oil occurs bonded to
carbon atoms, with a small amount occurring as elemental sulphur in solution and as hydrogen
sulphide gas. Sour oil can be toxic and corrosive, especially when the oil contains higher levels
of hydrogen sulphide, which is a breathing hazard. At low concentrations the gas gives the oil
the smell of rotting eggs. For safety reasons, sour crude oil needs to be stabilized by having
hydrogen sulphide gas (H2S) removed from it before being transported by oil tankers.

TAN Number:
The total acid number (TAN) is a measurement of acidity that is determined by the amount of
potassium hydroxide in milligrams that is needed to neutralize the acids in one gram of oil. It
is an important quality measurement of crude oil. The TAN value indicates to the crude oil
refinery the potential of corrosion problems. TAN values may also be useful in other industries
where oils are used as lubricants to determine oxidation and the subsequent corrosion risk to
machinery. TAN value can be deduced by various methods, including:

➢ Potentiometric titration
➢ Colour indicating titration
➢ Spectroscopic methods

Most preferable Crude Oil is Sweet and Light but as the Crude is Sweet and light the price of
that crude is increased by that parameter because the Quality also increases.

Sour Crude Oil Producing countries are: Alberta (Canada), United States' portion of the Gulf
of Mexico, Alaska and Mexico, Venezuela, Colombia, Ecuador, Saudi Arabia, Iraq, Iran,
Kuwait, Syria and Egypt.

Sweet Oil Producing countries are: UAE, Saudi Arabia, Iraq, Russia, Canada, UK, New
Zealand, China, Malaysia, Indonesia, Norway, Libya, Algeria, Nigeria, Scotland.

Crude Oil Have different names like Das, Murban, Arabian Light, Umme Shef, Umme Lulu,
American etc.

Cnergyico mostly use Murban or Arabian Light or sometimes Das (Good for making Diesel).

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 Unit Operations:
1. Crude Oil Distillation Unit:
The crude oil distillation unit (CDU) is the first processing unit in virtually all petroleum
refineries. The CDU distils the incoming crude oil into various fractions of different boiling
ranges, each of which are then processed further in the other refinery processing units. The
CDU is often referred to as the atmospheric distillation unit because it operates at slightly above
atmospheric pressure.

The incoming crude oil is preheated by exchanging heat with some of the hot, distilled fractions
and other streams. It is then desalted to remove inorganic salts (primarily sodium chloride).

Following the desalter, the crude oil is further heated by exchanging heat with some of the hot,
distilled fractions and other streams. It is then heated in a fuel-fired furnace (fired heater) to a
temperature of about 398 °C and routed into the bottom of the distillation unit

The cooling and condensing of the distillation tower overhead is provided partially by
exchanging heat with the incoming crude oil and partially by either an air-cooled or water-

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cooled condenser. Additional heat is removed from the distillation column by a pump around
system.

The overhead distillate fraction from the distillation column is naphtha. The fractions removed
from the side of the distillation column at various points between the column top and bottom
are called sidecuts. Each of the sidecuts (i.e., the kerosene, light gas oil and heavy gas oil) is
cooled by exchanging heat with the incoming crude oil. All of the fractions (i.e., the overhead

naphtha, the side cuts and the bottom residue) are sent to intermediate storage tanks before
being processed further.

Desalter:
In electrostatic desalting, crude oil is heated to decrease its viscosity. The crude oil is mixed
with Fresh water, which is dispersed in the crude oil as small droplets. The water-in-oil
dispersion is then introduced into the pressurized desalter vessel, where a high-voltage
electrical field accelerates separation of the water laden with salt and other contaminants
combined in the oil. Distributors feed the crude and emulsified water in two parallel horizontal
radial streams between the three electrodes. The oil emulsion streams flowing outward from
the distributor encounter optimal conditions for rapid coalescence. As coalescence proceeds,
water droplets grow large enough to overcome the viscosity of the crude and settle by gravity.
Electrodes are engineered to maximize the performance of the dual horizontal distribution
system.

The distribution system also allows for aggressive mixing, with a specialty valve, of the wash
water and crude oil so that when coalescence occurs, more impurities are removed with the
water and cleaner treated product is realized. The strong electric field is also less dependent on
chemicals for water droplet coalescence, so lower chemical consumption is typical.

Clean oil, freed of contaminants, continuously rises to the top of the vessel and flows out, while
the accumulated water and sediment mixture is removed from the bottom of the desalter for
disposal. The dual horizontal distribution system gives the BILECTRIC desalter significantly
better treating capacity compared with a conventional desalter and enhances the control of
interface emulsion.

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Distillation Column:
A distillation column is an essential item used in the distillation of liquid mixtures to separate
the mixture into its component parts, or fractions, based on the differences in volatilities.
Fractionating columns are used in small scale laboratory distillations as well as large scale
industrial distillations.

There are two types of Distillation Columns:

• Batch Distillation

• Continuous Distillation

The liquid mixture that is to be processed is known as the feed and this is introduced usually
somewhere near the middle of the column to a tray known as the feed tray. The feed tray divides
the column into a top (enriching or rectification) section and a bottom (stripping) section. The
feed flows down the column where it is collected at the bottom in the reboiler.

Heat is supplied to the reboiler to generate vapour. The source of heat input can be any suitable
fluid, although in most chemical plants this is normally steam. In refineries, the heating source
may be the output streams of other columns. The vapour raised in the reboiler is re-introduced
into the unit at the bottom of the column. The liquid removed from the reboiler is known as the
bottom’s product or simply, bottoms.

The vapour moves up the column, and as it exits the top of the unit, it is cooled by a condenser.
The condensed liquid is stored in a holding vessel known as the reflux drum. Some of this
liquid is recycled back to the top of the column and this is called the reflux. The condensed
liquid that is removed from the system is known as the distillate or top product.

Thus, there are internal flows of vapour and liquid within the column as well as external flows
of feeds and product streams, into and out of the column.

In Cnergyico Continuous Distillation is performed and Trays used are Bubble Cap Trays which
are 37 is number.

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2. Naphtha Hydrotreating Unit:
In Cnergyico the Top Product of Distillation Column is Full Range Naphtha which comes to
the Naphtha Hydrotreating Unit ranging from C1 to C12. In NHT we Hydro treat this Naphtha
And impurities like Sulphur, Nitrogen, Oxygen, Halides, Olefins, Metals are present in this
Naphtha.

First the Feed goes into the Feed Surge Drum where it is stored and Hydrogen from Platformer
Unit comes into the Fin Fan Coolers and then Knock Out vessel which is removing any
moisture present in Hydrogen because Moisture is not good for compressor. Then One line of
Hydrogen from Knock Out vessel goes into Compressor and One goes into Feed Surge Drum.
In Drum, Naphtha and Hydrogen both ate present which then is pumped through Centrifugal
Pumps and Hydrogen from Reciprocating Single Stage Double Acting Compressor is coming
into that line which then goes into pre–Heat Exchanger and after that into Furnace where its
temperature is raised and then it goes into Reactor.

In Reactor, six reactions are happening and Hydrogen is reacting with all the impurities.
Nickel/Molybdenum or Nickel/Cobalt is used as a Catalyst. Hydrogen with Oxygen making
H20, Hydrogen with Sulphur making H2S, Hydrogen with Nitrogen making NH3 which then
react with Halides to make Salts like NH4CL. Olefins are getting Saturated which then converts
into Paraffins, Metals are getting absorbed on the surface of Catalyst.

Now the Naphtha is called Treated Naphtha because the Impurities are not in Elemental form
where as they are bonding with Hydrogen which can be removed afterwards. The Treated
Naphtha is going into pre heat exchanger to exchange its heat with Cool Full Range naphtha
and then going into Fin/Fan Coolers and after that into Three Phase Separator which is
separating three products on the basis of their Density. On the Top the light gases like Fuel Gas
and LPG are removed, In between the Naphtha is present and at the bottom Brine water is
present which goes into Boot Water. Then Naphtha goes into Flash Drum where the pressure
is dropped due to which light gases is removed from the top and Treated Naphtha goes to Gas
Recovery Unit.

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PFD Of Naphtha Hydrotreating Unit:

3. Gas Recovery Unit:

Treated Naphtha from NHT, overhead Gas and Over Head Liquid from Platformer enters into
De-Ethanizer Column where due to specific Temperature and Pressure the C1 and C2
(Methane/Ethane) [Fuel Gas] is separated from Treated Naphtha (C1 to C12) and it goes into
Overhead Accumulator where fuel gas is separated from the reflux. Fuel gas from the top of
O/H Accumulator goes for furnace to be used as a fuel and reflux goes back to the top of De-
Ethanizer tower.

C3 to C12 goes into De-Butanizer where C3 and C4 (LPG) is separated and goes into Overhead
Accumulator where LPG containing H2S goes into MEA Absorber where Lean Amine from
Amine Regeneration Plant is flowed anti parallel to the feed and absorbs H2S from LPG. The
Lean Amine becomes Rich Amine and goes to Amine Regeneration Plant and LPG is stored
or could go into LPG splitter.

C5 to C12 from De-Butanizer goes into De-Isohexanizer where mostly C5 and some of the C6
is separated. C5 and C6 then passes from O/H Accumulator where Reflux goes back into
Column again and Light Naphtha (C5-C6) goes to Isomerisation Unit. Heavy Naphtha (C6 to
C12) goes to Platformer Unit by passing through Fin/Fan coolers.

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 PFD Of Gas Recovery Unit:

4. Amine Regeneration Unit:

To absorb H2S in MEA Absorber, we use MDEA (Mono diethanolamine). When MDEA
absorbs H2S it becomes Rich Amine which is then Regenerated/Treated in Amine
Regeneration Unit.

First it goes into Flash Drum where the pressure is lowered and some of the fuel gases are flash
out from Rich Amine then it goes into heat exchanger to raise its temperature and then enters
the Amine Regenerator Column where due to specific Temperature and Pressure H2S gas is
stripped Out from the top and Lean Amine is extracted out from the Bottom.

The H2S gas goes into the condenser where the liquid water particles are condensed and then
goes into O/H Accumulator where Reflux goes back into the Top of Column and H2S gas
containing moisture enters the Knock Out Vessel which separates the moisture and gas.

The Lean Amine from the Bottom of the Column goes into Reboiler. Some of it goes back into
the Column and remaining Amine passing through heat exchangers and condensers is stored in
Amine Storage Tank

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 PFD Of Amine Recovery Unit:

5. Reformer Unit:
Heavy Naphtha ranging (C6 to C12) coming from Gas Recovery Unit is coming to the
Platformer Unit. Platformer Unit consists of 4 Furnaces, 3 Reactors, 1 Stabiliser Column and
1 Reactor Product Separator. 2 of the 4 furnaces are Forced Draft and 2 are Natural Draft.

First the Heavy Naphtha goes into Pre-heat exchangers and then into 1st Furnace where its
temperature is raised and then it goes into 1st Reactor. After this the feed goes into 2nd Furnace
and then in 2nd Reactor and same is repeated for 3rd Furnace and 3rd Reactor.
After this the product from the reactor goes into condenser and then Reactor Product Separator
where, from the top, H2 is separated from the top, product goes into De Pentanizer Column by
passing through pre heat exchangers and Water from the bottom goes into Boot. H2 gas
containing Chlorine goes into De chlorination vessel where the chlorine is removed and H2 is
supplied to all units with a Centrifugal Three stage Compressor.

In De Pentanizer, O/H gas and O/H liquid is separated in the form of vapour from the top of
column where as Reformate (Petrol) flows from the bottom of Column. Some of the reformate

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 is reboiled and refluxed back to the bottom of column and some of it passes through condenser
for the storage.

The O/H gas and O/H liquid stripping from the top of column goes into O/H accumulator where
O/H gas (C1 and C2) and O/H Liquid (C3 and C4) is separated. Some of the O/H liquid goes
back to the top of Column in the form of reflux and remaining goes to Gas Recovery Unit.

Reactor:
There are 6 Reactions occurring in the reactors:
➢ De-Hydrogenation of Naphthene into Aromatics
➢ De-Hydro isomerization of Naphthenes into Aromatics
➢ Isomerization of Paraffins to Iso-paraffins
➢ De-Hydro cyclization of Paraffins
➢ Hydro Cracking
➢ Coke Formation / Carbon Deposition

Catalyst used in the reactor is Alumina Base with Platinum and Rhenium coated. The reactions
are Endothermic because Outlet temperature is less than of the Inlet.

In Platformer the petrol produced at the end has the RON (Research Octane Number) of 92.

PFD Of Reformer Unit:

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Conclusion:
It was a Wonderful Experience to be here and learn from the Experienced Ones. In a nutshell,
this internship has been an excellent and rewarding experience. I can conclude that there have
been a lot I’ve learnt from my work at Cnergyico. The Engineers and Operators taught me how
everything in the Plant works and also guided me for the future that on what Skill sets I should
focus and where the world is leading in the future so where should I aim for my better and
bright future. They treated me as a friend and colleague and co-operated with me which made
a learning environment for me. Being an Internee in an Oil Refinery like Cnergyico is a very
good option in my opinion because you learn more than you expected in only just One Month.
In this One Month I learned the different Equipment’s Operating parameters and their design
parameters, their problems and how to fix them, Equipments Insides and their parts, types of
Equipments, Selection Parameters of the Equipments, I also learned about Different Distillating
and Stripping Columns and how they are Operating. I learned about the Emergency drills and
how to perform them and what to do in Fire Emergency, which types of Extinguishers and
Hydrants are used in which type of Fire. Cnergyico’s Safety Parameters and Safety Rules are
very strict and Everyone (regardless of the designation) has to follow them. I believe my time
spent in research and discovering it was well worth it. I would Totally Recommend to every
Chemical Engineer to do One Month of Internship in Cnergyico if they get a chance.

Thank you

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