CONTENTS

ACKNOWLEDGEMENT
It has been a great privilege to be part of Indian Oil Corporation Limited, one of
the most prestigious public sector undertakings in India. IOCL's stature as the 83rd
largest public corporation in the world (as per the Fortune Global 500 list of 2012)
and the largest public corporation in India by revenue makes this training
experience all the more enriching and meaningful.
This acknowledgement is an opportunity to express my sincere gratitude to all
those who guided, supported, and inspired me throughout the course of this
vocational training.
I would like to extend my heartfelt thanks to the respective unit Shift in-charges
for their technical guidance and support:
Mr. Aman Thakur – Fire & Safety
Mr. Ravi Bhushan Kumar - Security
Mr. Sandesh Dagde – SPNM, BXP Block
Mr. Deepak Kumar – AVU III
Mr. Vinod Kumar - AVU I&II
Mr. Ajay Singh – LRU
Mr. Manish Singh - Coker A
Mr. Ram Prakash – RFCCU
Mr. Nitish Kumar – DHDT
Mr. K. Bisht – SRU
Mr. Pragati Kumar - OM&S
Their valuable insights into the functioning of each unit were instrumental in
enhancing my understanding of refinery operations.
I am also grateful to the technicians and field operators who supported me during
my time in the plant and patiently helped me connect theoretical knowledge with
practical industrial practices.
Lastly, I would like to thank my fellow trainees and the staff of Barauni Refinery for
their cooperation, camaraderie, and support throughout the training period.
 ABOUT IOCL

Indian Oil Corporation Limited (IOCL) is India’s largest integrated and diversified
energy company, playing a pivotal role in meeting the nation’s energy needs.
Founded in 1959, IOCL is a Maharatna public sector enterprise under the Ministry
of Petroleum & Natural Gas, Government of India.
IOCL’s operations span the entire hydrocarbon value chain — from refining,
pipeline transportation, and marketing of petroleum products to exploration &
production, petrochemicals, natural gas, and alternative energy initiatives. With a
pan-India presence, IOCL serves over a billion people through its vast network of
refineries, pipelines, fuel stations, and LPG distribution systems.
Key Highlights:
Fortune Global 500 Rank: Consistently featured in the Fortune Global 500 list;
ranked 83rd in 2012.
Refineries: Owns and operates 10 out of 23 refineries in India, with a total
refining capacity exceeding 80 MMTPA.
Pipeline Network: Operates the largest pipeline infrastructure in the country,
spanning over 15,000 km.
Market Share: Accounts for approximately 50% of India’s petroleum product
consumption.
Global Reach: Supplies petroleum products to neighboring countries like
Nepal, Bhutan, Sri Lanka, and Mauritius, and also maintains a presence in the
Middle East and Africa.
Innovation & Sustainability:
IOCL is deeply committed to sustainability and energy transition. The company is
investing in green hydrogen, electric mobility, biofuels, and renewable energy
projects to align with India’s vision of a cleaner energy future.
With a robust research and development division, IOCL continues to innovate in
areas such as fuel efficiency, emission reduction, and refinery automation. Its R&D
Centre in Faridabad is one of Asia’s finest in the field of petroleum technology.
 FIRE AND SAFETY TRAINING
Fire and Safety Department of Indian Oil Corporation Limited is concerned about the
fire hazards and safety of the company employees and labours. Fire and Safety
officials train the labours in a daily manner. A person can enter the Battery Area if
and only if he/she has a safety pass. This safety pass is issued by the Fire and Safety
Department officials only.

IMPORTANT TERMINOLOGIES:

Safety- Safety is a condition which gives us freedom from hazards, risk, accidents
which may cause injury, damage and loss of materials or property and even death.
Accident- It is an unexpected or unplanned event which may or may not result in
injury or damage or property loss or death.
Injury- It is defined as harmful conditions sustained by the body as a result of
accident.
Hazards- Inherent properties of a substance or an occurrence which has potential to
cause loss or damage of properties or life. Risk- Ill probability of the potential for loss
or damage or injury.

SAFETY MEASURES:

Different safety measures are taken to reduce the chances of hazards. Mobiles,
laptops, pen drives and cameras are prohibited inside the battery area. Cars which
are allowed to enter the battery area are provided with spark arrestors. Cigarette,
alcohol and other inflammable objects are not allowed inside the battery area. Fire
alarms and Fire Extinguishers are present within a considerable distance inside the
refinery. Workers are always advised to use their PPEs.
Personal Protection Equipment or PPEs Personal Protection equipment are
provided for the workers. These equipments are as follows:

Safety shoes/Gumboots for protection of feet.

Safety helmet for protection of head.
Face shield for protection of face.
Ear plug and ear muffs for protection of ears.
Hand gloves for protection of hands.
Apron for protection of body.
Dust mask for protection of nose.
Safety goggles for protection of eyes.
Safety belt for work at height.
 Personal Protective Equipment (PPE)

Use of PPE is strictly enforced in the refinery. Some of the essential PPE includes:

PPE Purpose

Safety Helmet Head protection from impact/falling objects

Safety Shoes/Gumboots Foot protection from heavy objects,

chemicals

Safety Goggles Eye protection from sparks, chemicals

Face Shield Facial protection during hot work

Hand Gloves Hand protection from burns/cuts

Dust Mask / Respirator Protection from dust and harmful gases

Ear Plug / Ear Muff Hearing protection in high-noise zones

Apron / Flameproof Suit Body protection during welding/hot jobs

Safety Harness / Belt Protection during work at height

Firefighting Systems and Equipment

The refinery is equipped with state-of-the-art fire protection and firefighting

systems, including:

Fixed Fire Hydrant Networks

Water Spray and Foam Systems
Dry Chemical Powder (DCP) Units
CO₂ Extinguishers (for electrical fires)
Foam Extinguishers (for flammable liquid fires)
Fire Tenders (Fire Engines) with water & foam tanks
Fire Control Room for monitoring alarms and rapid dispatch
 Hazard Siren Codes

Code Meaning

Continuous Siren (7:00 AM Daily) Test Alarm

Wailing Siren (2 mins) Major Fire Alert

Three Wailing Sirens (8 mins total) Disaster Alert (e.g., explosion, toxic release)

In the event of a siren, all employees are instructed to assemble at one of five
designated assembly points spread across the refinery.

Safety Measures and Protocols

Prohibition of mobile phones, cameras, USB drives, and metallic objects inside
hazardous zones.
Vehicles entering process areas must have spark arrestors.
Strict No Smoking/Alcohol/Drugs policy inside refinery premises.
Use of Work Permits (Hot Work, Confined Space Entry, Height Work, etc.) is
mandatory.
Periodic mock drills and emergency response exercises are conducted to
ensure preparedness.

Training and Awareness

The department regularly conducts safety training sessions for:

New employees and interns

Contractors and temporary workers
Fire crew and emergency responders

The Fire and Safety training instilled a clear understanding of the safety-first approach
required in industrial operations. It made us aware that safety is not just a protocol but a
mindset to be practiced every day. The hands-on exposure to firefighting tools and
emergency simulations gave us confidence in dealing with crisis scenarios, should they
arise.
OVERVIEW OF REFINERY
PROCESS
 STRUCTURE OF THE REFINERY

DEPARTMENTS JOB

1. PRODUCTION
Handles all production-related issues in the refinery.
DEPARTMENT

Encompasses Mechanical, Civil, Electrical, and

2. ENGINEERING SERVICE Instrumentation disciplines. Responsible for engineering
DEPARTMENT and material procurement activities for
modifications/process schemes/projects.

Conducts independent appraisal within the

3. INTERNAL AUDIT organization to review operations and support
management.

Provides technical backup to Production &

4. INSPECTION Maintenance departments. Monitors and inspects
DEPARTMENT static equipment (furnace, vessels, lines, columns) to
prevent failures and recommends necessary repairs.

Offers high-quality healthcare services to refinery

5. MEDICAL DEPARTMENT employees and their families. Provides assessment,
counseling, and expertise through skilled staff.

Minimizes losses related to machines, personnel,

6. FIRE & SAFETY materials, and the environment due to fire, accidents,
DEPARTMENT and disasters. Supports development of safe working
environments.

Offers technical support to production for monitoring

operations, fuel/losses, utilities, and chemicals. Also
7. TECHNICAL SERVICE
monitors emissions/effluents to meet environmental
regulations.

Monitors the quality of the crude input to the final

8. QUALITY CONTROL
refined products (e.g., MS, Diesel). Ensures
DEPARTMENT
compliance with product standards.
 PRODUCTION DEPARTMENT

Introduction
The Production Department serves as the heart of the refinery, where crude oil is
transformed into valuable petroleum products through a series of complex
refining processes. It is responsible for the continuous and efficient operation of
the refining units, ensuring optimal yield, product quality, and operational safety.
The department operates 24x7 and plays a crucial role in meeting market
demands, adhering to environmental standards, and maintaining smooth
coordination between upstream (crude procurement) and downstream (product
dispatch) activities.

Overview
The Production Department at IOCL Barauni Refinery comprises several
integrated units, each with a distinct function contributing to the refining process.
The department manages and monitors every stage — from crude distillation to
the treatment and blending of final products. The major units include:
Atmospheric & Vacuum Distillation Units (AVU-1, AVU-2, AVU-3): Primary
separation of crude into fractions like gasoline, kerosene, diesel, and reduced
crude oil.
Catalytic Reforming Unit (CRU): Converts low-octane naphtha into high-octane
gasoline and aromatic hydrocarbons.
Motor Spirit Quality Unit (MSQ): Enhances gasoline quality to meet Euro norms
by desulfurization and isomerization.
Diesel Hydrotreater Unit (DHDT): Removes sulfur from diesel to meet Bharat
Stage emission standards.
Delayed Coking Unit (DCU): Converts heavy residues into lighter hydrocarbons
and petroleum coke.
Resid Fluidized Catalytic Cracking Unit (RFCCU): Breaks down heavy
hydrocarbons into lighter products like LPG and gasoline.
Each of these units is operated under strict process control using advanced
Distributed Control Systems (DCS) and monitored for parameters like
temperature, pressure, flow, and composition.
Key Responsibilities of the Production
Department:

Process Control & Monitoring: Uses Distributed Control Systems (DCS),

Programmable Logic Controllers (PLC), and advanced sensors to monitor and
control process parameters (temperature, pressure, flow, and composition).

Coordination with Utilities: Works with the Utility & Technical Service
departments for steam, water, hydrogen, nitrogen, and power supply essential
for unit operation.

Environmental Compliance: Collaborates with the Environmental Monitoring

Cell to ensure effluent, emissions, and solid waste comply with statutory
norms.

Yield Optimization & Loss Minimization: Continuously works to improve

product yields while minimizing flaring, fuel consumption, and storage losses.

Emergency Handling & Safety Compliance: Operates under strict adherence to

refinery safety protocols and emergency handling procedures to ensure safe
operation of all pressurized and high-temperature equipment.

Blending & Storage: Manages blending of final products to meet quality specs
and interfaces with OM&S (Oil Movement and Storage) for dispatch and
inventory.

Conclusion
The Production Department is not just a processing unit—it is a dynamic system
involving high-level coordination, engineering control, and strategic decision-
making. It plays a critical role in transforming raw material into national assets by
maintaining a fine balance of efficiency, quality, safety, and environmental
stewardship.
The experience of observing and learning from the operations within this
department has been invaluable and deeply insightful for understanding large-
scale chemical process operations in real industry settings.
 ATMOSPHERIC & VACUUM
DISTILLATION UNIT ( AVU 1, 2 & 3)

Overview
The Atmospheric and vacuum Distillation units (AVUs) are also called primary or
mother units. The function of these units is to receive crude oil and treat them by
fractional distillation and recover their components. There are three AVUs in
Barauni Refinery, namely AVU-1, AVU-2 and AVU-3. AVU-1 and AVU-2 are designed
for handling sweet (low sulphur) crude only whereas AVU-3 is designed for handling
sweet as well as sour (high sulphur) crude. The columns and furnaces of AVU-3 are
lined with stainless steel for handling sour crude. AVU-2 has a special provision for
recovery of ATF (Aviation Turbine Fuel) (commercial name: JET A1) from crude oil
and also for LPG caustic wash.

Process flow diagram of AVU

Process Description
1. Crude Oil Pre-Treatment (Desalting)
Crude oil as received from the Refinery Tank Farm (RTF) contains dissolved
inorganic salts, sediment, and water. If not removed, these impurities—mainly salts
of Ca²⁺, Mg²⁺, Na⁺, and Cl⁻, SO₄²⁻—can cause severe corrosion, fouling, and catalyst
poisoning in downstream equipment.

Desalting Process Steps:

Crude oil (initially at ~30°C) is heated to 140–150°C in cold preheat exchangers,

recovering heat from outgoing product streams.
At a pressure of ~10 kg/cm², the heated crude is mixed with:
Water (4–5%) – dissolves the salts.
De-emulsifier (chemical surfactant) – promotes coalescence of water droplets.
The mixture enters the desalter, where it is subjected to a 12 kV electrostatic
field.
Water settles at the bottom as brine, while desalted crude (less than 1 PTB) exits
from the top.
pH control via ammonia, caustic, or acid dosing is also implemented to reduce
corrosion.

Outcome: Removal of salts, sludge, and mud ensures protection of heat

exchangers, columns, and downstream catalytic units.

2. Pre-Topping Column (K-1)

Desalted crude at ~230°C is flashed into vapor and liquid phases in the Pre-Topping
Column. This step:

Increases energy efficiency.

Recovers unstabilized naphtha and lighter ends before main fractionation.

Key Features:

Overhead vapors (naphtha and LPG) are condensed and collected at 45°C in the
3-way reflux vessel.
Reflux is split:
1. One part returns to the column to control overhead temperature.
2. The other is sent to naphtha caustic wash.
 Kerosene is drawn as a side stream:
1. Part goes to kero stripper (removes light ends via steam).
2. Remaining is recycled as circulating reflux to maintain column heat via
exchangers.
LPG and LGO crudes are handled similarly with LGO cr condensed and
recycled.

3. Main Fractionator (K-2)

The pre-topped crude enters the Main Atmospheric Fractionating Column, where
it is separated into valuable products based on boiling range.

Operating Principle:

Temperature decreases from bottom (~350°C) to top (~100°C).

Stripping steam is injected at the bottom to reduce hydrocarbon boiling points
via partial pressure reduction.

Product Streams:

Overhead: Stabilized gasoline/naphtha → cooled in air and trim condensers →

collected at 45°C → sent to caustic wash or returned as reflux.
Side Streams:
1. Kerosene → partially sent to kero stripper, remainder recycled.
2. LGO & HGO (Light/Heavy Gas Oil) → split into products and circulating reflux.
Bottom Product: Reduced Crude Oil (RCO) → reheated (~360°C) and sent to
Vacuum Distillation Column.

4. Naphtha Stabilizer Column (K-4)

Overhead product from K-1 (naphtha + LPG) enters this column to:
Remove light ends (propane, butane) to lower naphtha vapor pressure.
Prevent vapor lock in vehicle engines.

Process Flow:
Light hydrocarbons are stripped and cooled.
Part of condensed LPG is recycled, the rest sent to LPG Recovery Unit (LRU).
5. Vacuum Distillation Column
RCO from the main fractionator is not suitable for direct heating due to risk of
thermal cracking. Instead, it is fed into a Vacuum Distillation Column, which
operates under reduced pressure to enable further fractionation at lower
temperatures.

Key Features:

Overhead vapors → condensed in pre-condenser, ejectors handle steam/non-

condensables.

Side Streams:

1. LVGO & HVGO (Light and Heavy Vacuum Gas Oil) → used as feeds for RFCCU,
DHDT, etc.
2. Internal reflux is used to maintain temperature profile.

Bottom Product:

1. Short Residue (SR) → sent to Coker Unit or Resid FCCU after heat recovery.
2. Acts as fuel or feedstock for secondary processing.

Vacuum System:

Maintained via steam ejectors, allowing reduced boiling points.

Demister installed at top to prevent entrainment in vapors.

Vacuum Distillation

The atmospheric residue is introduced into a Vacuum Furnace and then into the
Vacuum Distillation Column.
Operation under reduced pressure (~30–50 mmHg) allows vaporization at lower
temperatures (~400°C), avoiding thermal cracking.
The vacuum column separates:
Light Vacuum Gas Oil (LVGO)
Heavy Vacuum Gas Oil (HVGO)
Vacuum Residue (VR)
Main Products From AVU

Fraction Boiling Range Use

LPG and Fuel Gas < 40°C Fuel, domestic gas

Naphtha 40–180°C Petrochemical feedstock,

MS blending

Kerosene 180–250°C Aviation turbine fuel (ATF)

Diesel 250–370°C High-speed diesel (HSD)

AGO/LVGO/HVGO 370–550°C Feed for catalytic

cracking/hydrotreating

Vacuum Residue (VR) >550°C Feed for Delayed Coking

or Bitumen

The AVU sets the stage for the entire refining process. It supplies feedstock to
almost every downstream unit like the:

Catalytic Cracking Unit (RFCCU)

Diesel Hydrotreater (DHDT)
Naphtha Hydrotreaters
Delayed Coking Unit (DCU)

Significance of AVU

The AVU is the first and most critical step in the petroleum refining process. It:

Enables efficient recovery of major petroleum fractions.

Reduces burden on downstream units by segmenting the crude into
manageable cuts.
Enhances energy integration through heat recovery systems.
Plays a key role in optimizing refinery throughput and yield.
 CATALYTIC REFORMING UNIT
(CRU)

Introduction
The Catalytic Reforming Unit (CRU) at IOCL Barauni Refinery plays a crucial role in
enhancing the octane rating of gasoline. It processes heavy naphtha streams into
high-octane reformate, which is a vital blending component in petrol. Alongside
reformate, the CRU also generates aromatic hydrocarbons (like benzene, toluene, and
xylene) and hydrogen, both of which are valuable by-products used elsewhere in the
refinery.
CRU is a secondary processing unit and is essential in meeting stringent fuel quality
specifications, particularly those related to octane number, aromatic content, and
volatility standards.

Feedstock
Heavy straight-run naphtha (IBP ~ 140°C) obtained from distillation units.
The feed is first treated to remove impurities like sulfur, nitrogen, oxygen, water,
olefins, and heavy metals, which can poison the catalyst used in the reforming
process.

Process Overview
The CRU process can be broadly divided into the following stages:

1. Feed Preparation and Hydro-Treating

Hydrotreater Unit (HTU): Removes sulfur, nitrogen, and olefins from naphtha
using hydrogen gas in presence of Co-Mo or Ni-Mo catalysts supported on
alumina.
Typical reactions include:
a. Desulfurization:
R-SH + H₂ → R-H + H₂S
b. Denitrification:
R-NH₂ + H₂ → R-H + NH₃
Hydrogenation of olefins and di-olefins into paraffins.
2. Catalytic Reforming Process

After hydrotreating, the feed enters the reforming reactors. There are typically
three fixed-bed reactors in series, each operating at high temperature (~500–
520°C) and moderate pressure.

Main chemical reactions:

Dehydrocyclization:
Converts paraffins into aromatics.
n - H e p t a n e → To l u e n e + H ₂
Dehydrogenation of naphthenes:
M e t h y l c y c l o h e x a n e → To l u e n e + 3 H ₂
Isomerization of paraffins:
n-Pentane → isopentane

Side reactions (to be minimized):

Cracking
Hydrocracking
Coking
Alkylation

The reforming catalyst used is a bimetallic combination of platinum and rhenium

on an alumina support.

3. Separation and Recovery

The effluent from the reactors is cooled and sent to a separator, where:
Hydrogen-rich gas is recovered and recycled to the reactors.
Liquid reformate is stabilized in a stabilizer column to remove light
hydrocarbons.
Final reformate product is routed to the gasoline blending pool.

Products of CRU

Reformate: High-octane component for petrol blending.

Hydrogen Gas: Used in hydrotreating units (like DHDT, MSQ).
Aromatics: Feedstock for petrochemicals (BTX – Benzene, Toluene, Xylene).
LPG & Light Ends: Used as refinery fuel or treated further.
Importance in the Refinery

Increases octane number of motor spirit, critical for meeting BS-VI fuel
standards.
Produces hydrogen required by other process units (self-sustaining loop).
Enhances product value and refinery flexibility in crude processing.

Safety & Operation

Operates under high pressure and temperature; requires robust catalyst

handling and temperature control.
Hydrogen handling involves safety risks—leak detection and fire safety systems
are essential.
Catalyst regeneration may be required periodically to maintain activity and
prevent deactivation by coke deposits.

Conclusion

The CRU is a technologically sophisticated and strategically significant unit in the

refinery. It enhances the overall product quality and value while also supporting
other units with hydrogen supply. During training, I observed the complex control
mechanisms and the critical role played by catalysts and separation units in
maintaining the efficiency and output quality of this unit.
 BXP COOLING TOWER &
ASSOCIATED UNITS
The BXP (Barauni Expansion Project) Cooling Tower is a critical utility system at
IOCL Barauni Refinery. It provides cooling water to multiple high-temperature
process units.
The BXP Cooling Tower is a heat-rejection system that removes waste heat from
process water using evaporative cooling. Hot water from heat exchangers is
sprayed over fill media, while air is blown upward by fans. A small portion of water
evaporates, absorbing heat and cooling the remaining water, which is then
collected and recirculated.
Key Features:
Induced/forced-draft fans
Make-up water system
Drift eliminators
Water treatment systems to prevent scaling and microbial growth

Unit Feed Product

Residue Fluidized
Blend of short residue Fuel gas oil, LPG,
Catalytic Cracking Unit
and HVGO gasoline
(RFCCU)

Diesel Hydro Treating High sulfur, low cetane Low sulfur, high cetane
Unit (DHDTU) diesel diesel

Hydrogen Generation
Naphtha Hydrogen (99.99% pure)
Unit (HGU)

Rich amine containing

Amine Recovery Unit
high levels of H₂S (from Lean amine
(ARU)
DHDT/RFCCU)

Sour Water Stripping

Sour water Treated water
Unit (SWSU)

Sulfur Recovery Unit

Acid gas feed Elemental sulfur
(SRU)

Reformate (motor spirit

Catalytic Reforming Unit
Gasoline component) and
(CRU)
hydrogen
 HYDROGEN GENERATION UNIT
(HGU)

Overview
The Hydrogen Generation Units were established under the Barauni Expansion
Project (BXP) in the year 2001. Hydrogen is required for the removal of sulfur
present in fuel oils and is used by units like DHDT and CRU. A fraction of the
generated hydrogen is also consumed by the HGU itself. Indian Oil Corporation
Limited, Barauni Refinery is equipped with two Hydrogen Generation Units,
namely HGU-1 and HGU-2, with a combined capacity of approximately 54
kilotonnes per annum (ktpa). As a fuel, hydrogen has a very high calorific value of
141,790 kJ/kg. As a result, this plant is handled with extreme care and precaution.
The reformer of the HGU is equipped with 118 burners, capable of heating
feedstock up to 900 °C, with provisions to use 1400 °C-grade naphtha as auxiliary
fuel.

Process
The Hydrogen Generation Unit at IOCL Barauni Refinery produces high-purity
hydrogen primarily through the steam reforming of naphtha. The process
involves the following main steps:
1. Desulfurization:
The naphtha feed is first treated to remove sulfur compounds using a
hydrogenation reactor, as sulfur can poison the reforming catalyst.
2. Preheating & Vaporization:
The desulfurized naphtha is mixed with steam and preheated using heat
exchangers and fired heaters.
3. Steam Reforming:
The mixture is passed through a reformer furnace containing catalyst-filled
tubes. At high temperatures (~800–900 °C), hydrocarbons react with steam to
form hydrogen (H₂), carbon monoxide (CO), and carbon dioxide (CO₂).
4. Shift Conversion:
CO is further reacted with steam in the shift converter to produce additional
hydrogen and CO₂.
5. Gas Cooling & Separation:
The gas is cooled and passed through knock-out drums to remove water and
other condensable.
6. Purification (PSA Unit):
The gas mixture enters a Pressure Swing Adsorption (PSA) system that separates
pure hydrogen from impurities like CO, CO₂, methane, and nitrogen.
The final product is high-purity hydrogen (~99.9%) which is then supplied to units
like DHDT and CRU, with a portion used internally.

SULPHUR RECOVERY UNIT

(SRU)
Overview
Hydrogen Sulphide also referred to as ‘sour gas’ or ‘acid gas’ is commonly present
in natural gas and oil formations. At low concentrations, it smells like rotten eggs.
It is EXTREMELY dangerous as it is heavier than air, impairs our ability to
smell/detect with increasing concentration, and exposure to >500 ppm can be
fatal! With respect to safety and product specifications, it must be removed from
natural gas and petroleum products. The Sulphur Recovery Unit in the Refinery
takes care of the sour off gases from the various units for removal of Hydrogen
Sulphide. This is done by Amine treatment after which sulphur is recovered from
the off gases.

Feedstock
Rich amine from RFCCU, DHDT, LPG and Coker.
Process
1. Amine Recovery Unit (ARU)
Function: Extracts H₂S and CO₂ from refinery gas streams using a chemical
solvent (amine solution, such as MDEA or DEA).
Operation:
Rich amine (loaded with H₂S and CO₂) is heated in a regenerator (stripper).
H₂S and other light gases are stripped and sent to the Claus section.
Lean amine is cooled and recycled to gas absorbers in DHDT, RFCCU, and
other units.
Key Reactions:
R₂NH·H₂S → R₂NH + H₂S
(R₂NH)₂CO₃ → R₂NH + CO₂ + H₂O

2. Sour Water Stripper Unit (SWSU)

Function: Processes sour water (wastewater containing H₂S and NH₃) from
refinery units.
Operation:
Steam stripping is used to remove H₂S and NH₃.
Stripped gases are directed to the SRU for further treatment.

3. Sulfur Recovery Section (Claus Process)

Function: Converts H₂S-rich gases into elemental sulfur.
Process Steps:
a. Thermal Stage:
One-third of H₂S is combusted with air to form sulfur dioxide (SO₂):
2H₂S + 3O₂ → 2SO₂ + 2H₂O
b. Catalytic Stage:
Remaining H₂S reacts with SO₂ over a catalyst to form elemental sulfur:
2H₂S + SO₂ → 3S + 2H₂O
c. Condensation:
The hot reaction gases are cooled in stages, and sulfur is condensed
and collected.
Output: Elemental sulfur is recovered as liquid and can be further solidified for
storage or sale
.
4. Liquid Nitrogen Unit
Function: Supplies nitrogen to purge process lines and equipment to prevent
the formation of explosive mixtures.
Application: Used during startup, shutdown, or maintenance operations for
safety and inerting.
 DIESEL HYDRO-TREATING
UNIT (DHDT)
Overview
The main purpose of the DHDT unit is to hydro treat the diesel components from
atmospheric and vacuum units, Delayed Coker unit and fluidized catalytic cracking
unit to produce HSD meeting EURO-III/IV specifications. The product diesel will
have minimum cetane number of 51 and sulphur content less than 0.05% by
weight. The other process objectives of the DHDT unit are the stabilization of the
wild naphtha generated in the unit such that it can be routed to refinery gasoline
pool & the amine treatment of the sour off gases produced in the unit.

Feedstock
Feed from SRK-II, Coker and OM & S.

Process
1. Feed Preparation:
Straight-run diesel and cracked diesel streams are mixed, filtered, and preheated
using heat exchangers.

2. Hydrotreating Reactor:
The preheated diesel is mixed with high-purity hydrogen and passed over a
catalyst (typically Co-Mo or Ni-Mo on alumina) inside a fixed-bed reactor at:
Temperature: 300–380 °C
Pressure: 30–80 bar
Under these conditions, sulfur- and nitrogen-containing compounds are
hydrogenated and converted into hydrogen sulfide (H₂S), ammonia (NH₃), and
hydrocarbons.

3. Separation:
The reactor effluent is cooled and sent to a high-pressure separator. Hydrogen-
rich gas is recycled, and the liquid product is routed to a stripper.

4. Stripping & Product Recovery:

The diesel product is stripped with steam to remove dissolved gases like H₂S and
NH₃, producing clean ultra-low sulfur diesel.
Key Chemical Reactions
1. Hydrodesulfurization (HDS):
R–S–R' + 2H₂ → R–H + R'–H + H₂S

2. Hydrodenitrogenation (HDN):
R–NH₂ + H₂ → R–H + NH₃

3. Hydrogenation of Aromatics (optional):

Aromatic Ring + H₂ → Saturated Cycloalkanes (enhances cetane number)
 LPG RECOVERY UNIT (LRU)
Overview
The Light Rerun Unit (LRU) is an essential auxiliary unit in a petroleum refinery,
primarily used to improve product quality by re-distilling light hydrocarbon
streams. Its main objective is to separate desirable components from light-end by-
products and off-spec materials, enhancing recovery and meeting product grade
specifications.
The LRU typically handles light naphtha, off-spec gasoline, or light hydrocarbons
from other units like:
Catalytic Reforming Unit (CRU)
Diesel Hydrotreater (DHDT)
Motor Spirit Quality (MSQ) Unit
LPG treatment and stabilization sections

Feedstock
Off gases from AVUs and the Coker Unit is the feed of LPG Recovery Unit.

Process
1. Feed Preheating:
The incoming stream is preheated using heat exchangers, often recovering heat
from the product streams.

2. Fractionation:
The preheated feed is sent to a distillation column (reboiler-equipped). This
separates the stream based on boiling point differences:
Overhead: light ends like C₃/C₄, naphtha, or LPG
Side-draws (optional): treated naphtha fractions
Bottoms: heavier or off-spec material returned to other units (e.g., MSQ or
AVU)

3. Condensation & Cooling:

The overhead vapors are condensed and collected in a reflux drum. Part of the
condensate is returned to the column as reflux, and the rest is sent for storage or
blending.

4. Product Handling:
Final products are routed to tanks, further treatment, or blending systems
depending on refinery needs.
 RESID FLUIDIZED CATALYTIC
CRACKING UNIT (RFCCU)

Overview
Refineries differ in complexity; more advanced ones use secondary conversion
units to maximize product output. The Resid Fluidized Catalytic Cracking Unit
(RFCCU) is one such unit, used to convert heavy hydrocarbons into lighter
products like gasoline using a fluidized catalyst bed. At IOCL Barauni Refinery, the
RFCCU—commissioned in 2001 under the Barauni Expansion Project (BXP)—
processes short residue (SR) and Heavy Vacuum Gas Oil (HVGO) from the Vacuum
Distillation Unit to enhance gasoline yield.

Feedstock
Short Residue and Heavy Vacuum Gas Oil is the feed of RFCCU. This is heated in a
heat exchanger before feeding it in the Reactor.

Process
1. Feed Pre-treatment:
The feedstock (mainly VGO or cracked residue) is preheated and injected into the
reactor’s riser section along with hot regenerated catalyst.

2. Catalytic Cracking (Riser-Reactor):

In the riser reactor (~500–550 °C), heavy hydrocarbons undergo thermal and
catalytic cracking in the presence of fluidized catalyst. The reaction is short-
contact, high-velocity (~2–5 seconds), ensuring maximum yield of lighter products.

3. Separation:
Cracked hydrocarbon vapors are quickly separated from spent catalyst in
cyclones. Vapors are sent to the main fractionator for product separation. Spent
catalyst flows to the regenerator.

4. Catalyst Regeneration:
The catalyst is stripped of hydrocarbons using steam and sent to a regenerator,
where coke deposited during cracking is burned off in the presence of air. This
reheats the catalyst for reuse and generates flue gas.
5. Product Fractionation:
The cracked vapors are distilled in the main fractionator into:
LPG
Gasoline
Light Cycle Oil (LCO)
Clarified Slurry Oil (CSO)

MAIN FRACTIONATING COLUMN:

The reaction product vapours (at 535 oC and 1.72 bars) flow from the top to the
bottom section of the distillation column where they are distilled into several
fractions:
1. The off gas (mainly C1-C2) from the top goes to the LPG Recovery Unit.
2. The C3-C4 fractions go to LPG Treatment Unit.
3. Light Cracked Naphtha (LCN) and Heavy Cracked Naphtha (HCN) are sent to
Motor Spirit (MS) pool.
4. Light Cycle Oil (LCO) and Heavy Cycle Oil (HCO) is sent to Diesel Hydro
treatment Unit (DHDT).
5. Decant Oil (DCO) is sent to Carbon Black Feed Stock (CBFS).

Process Body Diagram of RFCCU

 COKER - A&B

Overview
Refineries differ in complexity; more advanced ones use secondary conversion
units to maximize product output. The Resid Fluidized Catalytic Cracking Unit
(RFCCU) is one such unit, used to convert heavy hydrocarbons into lighter
products like gasoline using a fluidized catalyst bed. At IOCL Barauni Refinery, the
RFCCU—commissioned in 2001 under the Barauni Expansion Project (BXP)—
processes short residue (SR) and Heavy Vacuum Gas Oil (HVGO) from the Vacuum
Distillation Unit to enhance gasoline yield.

FEEDSTOCK:
Feedstock can have a considerable amount of metal (Ni + V), Sulphur, Resins and
Asphaltenes. Most typical feedstock is Vacuum Residue. It can also process
refinery slop oil/sludge. Atmospheric residue is also occasionally processed.

Delayed Coking Process

In the Delayed Coking Unit, the heavy residue feedstock is pumped from the coker
feed tanks (located outside the battery limit) to a feed surge drum, which also
receives hot short residue and other return streams. From the surge drum, feed is
sent to the Main Fractionator, where it is preheated to around 240°C using
kerosene, LDO product, and circulating reflux in heat exchangers.
The preheated feed, along with a 70% recycle stream (in 100:70 ratio), is pumped
to the bottom section of the coker furnaces, where it's heated further to 315–
320°C. Turbulising water is injected to enhance flow, minimize coke buildup in
furnace tubes, and improve heat transfer.
The hot mixture exits the furnace radiation zone and enters two coke drums (coke
chambers) via 4-way switch valves. The coking reaction occurs inside these drums,
where thermal cracking at high temperature and long residence time converts
heavy hydrocarbons into vapor and solid petroleum coke. Vapors exit from the top
and move to the quench column, while the unvaporized portion forms coke.
Coke drums operate alternately—while one is on-stream, the other undergoes
steam stripping, cooling, or coke removal. Anti-foam injection is provided to
control foaming during operation. Vapors from the coke drum are quenched with
LDO to reduce temperature and minimize coke formation in downstream lines.
Typical coking cycles range from 16 to 24 hours, depending on unit design and
feed conditions.
 Process flow Diagram of Coker

PRODUCTS OF DELAYED COKING:

1. Delayed coker produces desirable liquid products (naphtha and gas oil) and by-
products and by-products coker gas and solid coke.
2. Coker off-gas goes to the gas plant where C3 and C4 are recovered as LPG and
the lighter end can be used as fuel gas in the refinery.
3. Naphtha contains high olefin content and this stream is usually sent to
hydrotreater for stabilization.
4. Light Coker Gas Oil (LCGO) is sent to diesel hydrotreater for production of diesel.
Typical end point of this stream is around point of this stream is around 370 °C.
5. Heavy Coker Gas Oil (HCGO) is sent to FCC/ RFCC for production of valuable
distillate products. Typical end point of this stream is around s around 538 °C
 OM&S (OIL MOVEMENT &
STORAGE)

Overview
OM&S is the transportation hub for the whole refinery, without raw products
would not be received and the products made would never reach the market. It is
one of the units which actively works with IOCL (Marketing Division).
OM&S Collaborates With The Marketing Division, According, To The Current Market
Demands And That Of Other Indian Refineries, Make Projections And Imports The
Crude Accordingly And Similarly Dispatch Products To Market To Meet With Its
Demands.

OM&S Collaborates With The Marketing Division, According, To The Current Market
Demands And That Of Other Indian Refineries, Make Projections And Imports The
Crude Accordingly And Similarly Dispatch Products To Market To Meet With Its
Demands.

OM&S comprises of 3 following units:

1. Receipt
2. LPG Control
3. Dispatch

Receipt Unit
The Receipt section handles the unloading and transfer of incoming crude oil and
other feedstocks into the refinery’s tank farm.
Crude oil is received via pipelines from Haldia Port or through rail wagons.
Additives and blending components may also be received and stored here.
Flow control, measurement (using flow meters), and sampling are performed
to ensure proper accountability.
Tanks are regularly monitored for temperature, water content, and volume.
The received crude is then transferred to the Atmospheric & Vacuum Distillation
Units (AVU) for processing.
LPG Control Unit
This section monitors and regulates the storage, blending, and dispatch of
Liquefied Petroleum Gas (LPG), one of the key high-value products of the refinery.
LPG is stored in large pressurized bullet tanks or spheres.
Flow and pressure control systems maintain stability during bottling and
loading operations.
The LPG composition is regulated to meet regulatory and safety standards.
Safety is paramount—LPG handling zones are flameproof and equipped with
gas leak detectors, fire suppression systems, and emergency shutdown
systems.
Bottling plant coordination ensures efficient dispatch for domestic and
commercial use.

Dispatch Unit
The Dispatch unit oversees the final stage of the product lifecycle in the refinery:
moving finished petroleum products to the market.
Products like Motor Spirit (petrol), High-Speed Diesel (HSD), ATF, kerosene, and
LPG are dispatched via:
Pipeline (to terminal stations and depots)
Rail wagons
Tank trucks
Each dispatch is logged, metered, and certified by quality control before
leaving the refinery.
The unit ensures strict adherence to product quality, quantity, and safety
standards.
Dispatch planning is integrated with real-time inventory systems and
marketing requirements.
 Conclusion

The vocational training at Indian Oil Corporation Limited, Barauni Refinery was an
enriching and eye-opening experience that significantly broadened my
understanding of real-world industrial operations. As a chemical engineering
student, this training served as a bridge between theoretical knowledge and
practical applications, offering insights into how complex refinery processes are
executed, controlled, and optimized at a large scale.

Throughout the training, I had the opportunity to observe and learn from various
critical units such as the Atmospheric and Vacuum Distillation Units (AVUs),
Catalytic Reforming Unit (CRU), Diesel Hydrotreater Unit (DHDT), RFCCU, Delayed
Coker, Sulfur Recovery, and Hydrogen Generation Units. Each of these units
highlighted the intricate integration of chemical reactions, process design, energy
management, safety practices, and environmental compliance.

The professionalism, discipline, and safety culture followed within the refinery
have left a lasting impression. The use of advanced instrumentation, automation
systems (like DCS), and strict adherence to environmental and safety norms
reflect IOCL’s commitment to excellence and sustainability.

This training not only deepened my understanding of process engineering and

plant operations but also improved my observational, analytical, and
interpersonal skills. It gave me a clearer perspective on career opportunities in the
oil & gas sector and reinforced my interest in pursuing a future in process
engineering and plant design.

I am extremely grateful to the IOCL Barauni Refinery team for their mentorship
and support, and I consider this training a valuable milestone in my academic and
professional journey.