INTERNSHIP REPORT
On
Return Advanced Petroleum Refinery
Submitted by:
K. Rithishkumar
B.E. Chemical Engineering
Organized by:
Terra Green Training Institute
Duration:
4 Weeks (Online)
1. Introduction
The evolution of engineering education has increasingly emphasized
the importance of industry-academic collaboration to bridge the gap
between theoretical knowledge and practical experience. Internships provide
this bridge by immersing students in real-world environments, enabling them
to understand industrial operations, challenges, and solutions through direct
engagement.
As part of this vision, I had the opportunity to participate in a 4-week online
internship organized by Terra Green Training Institute. The internship focused
on "Return Advanced Petroleum Refinery," specifically covering downstream
processes in the petroleum refining sector. The internship was delivered
virtually and included detailed lectures, flow diagrams, industrial case
studies, and technology reviews conducted by D. Chakraborty, a retired Chief
General Manager of IOCL, Gujarat Refinery.
The aim of this internship was to impart deep insights into advanced
petroleum refining operations, particularly emphasizing process integration,
modern configurations, environmental compliance, and optimization of units
like distillation, catalytic reforming, and hydroprocessing. It also highlighted
sustainability and energy efficiency goals.
Through the online delivery format, the program effectively blended visual
aids, technical presentations, and case-based learning, making the
knowledge both accessible and engaging. This report summarizes the topics
covered, the technical learnings gained, and key observations from the
internship.
2. Industrial Processes &
Applications
The petroleum refinery is a complex integration of primary, secondary, and
tertiary processes designed to transform crude oil into various valuable
products such as LPG, gasoline, diesel, ATF, lubricants, bitumen, and
petrochemical feedstocks.
2.1 Crude Distillation & Desalting
One of the most fundamental operations is Atmospheric and Vacuum
Distillation (AVU). It separates crude oil into fractions based on boiling point.
The Desalter unit removes salts and impurities before crude enters the
furnace.
➤ Atmospheric Distillation (CDU)
Products: LPG, Light Naphtha, Heavy Naphtha, Kerosene, Diesel, and
Reduced Crude.
Operates at around 370–390°C.
➤ Vacuum Distillation (VDU)
Uses low pressure (25–40 mmHg) to prevent thermal cracking.
Produces Vacuum Gas Oil (VGO), Vacuum Slop, and Vacuum Residue.
Diagram Reference: Atmospheric & Vacuum Distillation Unit Flow Diagram
2.2 Diesel Hydrotreating Unit
This is a secondary treatment process aimed at reducing sulfur, nitrogen,
and aromatics in diesel to meet Euro-VI norms.
Feedstock: Straight-run diesel, FCC diesel, Visbreaker diesel
Operating Pressure: ~100 kg/cm²
Catalyst: Ni-Mo or Co-Mo oxides
Key Reaction: Desulfurization (H₂ + S → H₂S)
Diagram Reference: Diesel Hydrotreator Unit Flow Diagram
2.3 Continuous Catalytic Reforming Unit (CCRU)
Used to convert low-octane naphtha into high-octane reformate, an essential
gasoline component.
Feedstock: 85–160°C cut naphtha
Temperature: ~520–540°C
Catalyst: Platinum or rhenium on alumina
Key Reactions: Dehydrogenation, Isomerization, Cyclization
Diagram Reference: Continuous Catalytic Reforming Unit Flow Diagram
2.4 Fluidized Catalytic Cracking Unit (FCCU)
A conversion unit where heavier feed like VGO is cracked into lighter
hydrocarbons using a fluidized bed of zeolite catalyst.
Products: LPG, Gasoline, Diesel
Reaction: Endothermic hydrocarbon cracking
2.5 Hydrocracker Unit (HCU)
Upgrades vacuum gas oil (VGO) to diesel, ATF, and naphtha through
hydrogen-rich atmosphere at high pressure.
Catalyst: Ni/Mo or Ni/W
Temperature: 370–420°C
Pressure: 160–170 kg/cm²
2.6 Visbreaker Unit
Reduces the viscosity of residual oil via mild thermal cracking.
Feed: RCO/Vacuum Residue
Output: Visbroken tar and gas oil
2.7 Treatment Units
Caustic Wash & Merox: Remove H₂S and mercaptans from LPG and
naphtha
Sour Water Stripper: Removes NH₃ and H₂S from process water
Sulfur Recovery Unit (SRU): Recovers sulfur via the Claus process
3. Case Study Analysis
Case Study: Delayed Coking Unit (DCU)
🔹 Objective
To upgrade heavy residual oil into lighter products and solid petroleum coke
through thermal cracking.
🔹 Feedstock
Vacuum Residue (VR)
Reduced Crude Oil (RCO)
🔹 Process Description
Heated to 495–505°C in a furnace.
Steam injection delays coking until it reaches coke drums.
Vapors sent to fractionator; solids left behind as coke.
🔹 Products
Gas, LPG
Coker Naphtha
Coker Gas Oil
Petroleum Coke
🔹 Challenges
Coke yield vs liquid product optimization
Cycle time & spalling requirements
Heater metallurgy & fouling control
🔹 Optimization Techniques
Steam stripping
Temperature control
COT vs run-length balance
Coke handling improvements
🔹 Learning Outcome
This case demonstrated the real-world complexity of managing bottom-of-
the-barrel upgrading, integrating chemistry, thermodynamics, and
mechanical integrity to achieve reliable performance.
4. Scope of Research and
Development
🔍 Innovation Areas
AI-Powered Process Control: Use of machine learning for predicting coke
deposition, optimizing catalyst performance.
Sustainable Feedstock Alternatives: Co-processing of bio-crudes or plastic
waste-derived oils.
Advanced Catalysts: Nano-structured or recyclable catalysts in
hydrocracking and reforming.
CO₂ Capture & Utilization: Retrofitting hydrogen and FCC units with
capture technology.
Modular Units: For flexible refining capacity in remote areas.
🔍 Recent Trends
Euro-VI compliant diesel
Shift to low-carbon fuels
Integration of digital twins for simulation
Energy-efficient heat exchanger networks
5. Summary
This internship provided a holistic understanding of downstream petroleum
refinery operations, integrating both classical processes and modern
enhancements. It emphasized:
Core principles of crude distillation
Detailed exploration of conversion and treatment units
Real-world case studies with optimization strategies
Through expert-led sessions and interactive visual aids, I developed an
improved grasp of process integration, flow design, and the critical role of
each unit operation in maximizing refinery profitability and environmental
compliance.
6. Observation / Opinion
My experience during the Terra Green Training Institute internship was
both enriching and technically rewarding. Despite being conducted online,
the content delivery was structured, clear, and deeply informative. The case
studies and diagrams helped link theoretical learning to actual industrial
practices.
This internship sharpened my understanding of reaction engineering,
thermodynamics, and process integration in real-world settings. I particularly
appreciated the detailed explanation of delayed coking and hydrotreating,
which expanded my awareness of emissions control and product upgrading.