A TECHNICAL REPORT ON

STUDENTS INDUSTRIAL WORK EXPERIENCE

SCHEME (SIWES)
UNDERTAKEN AT:

WARRI REFINING & PETROCHEMICAL COMPANY LIMITED

(WRPC)
BY:
IRABOR OSEDEBAMEN ITUA
U2007/3065261
DEPARTMENT OF PETROLEUM & GAS ENGINEERING
FACULTY OF ENGINEERING
UNIVERSITY OF PORT HARCOURT
INSTITUTION BASED SUPERVISOR:
ENGR. PRINCE WACHUKWU

FROM:
AUGUST 15th 2011 TO FEBRUARY 12th 2012
SIWES REPORT

TABLE OF CONTENTS

TABLE OF CONTENTS ............................................................................................................................................................................. 2

LIST OF FIGURES.................................................................................................................................................................................. 4
LIST OF TABLES ................................................................................................................................................................................... 4
CHAPTER 1 ................................................................................................................................................................................................... 5
1 INTRODUCTION ............................................................................................................................................................................... 5
1.1. HISTORY OF SIWES ............................................................................................................................................................ 5
1.2. AIMS AND OBJECTIVES OF SIWES ............................................................................................................................... 6
1.3. THE COMPANY ..................................................................................................................................................................... 7
1.4. HISTORY OF THE ORGANIZATION .............................................................................................................................. 7
1.5. ORGANIZATIONAL CHART .............................................................................................................................................. 8
1.6. BRIEF DESCRIPTION OF THE UNITS .......................................................................................................................... 9
1.7. FUNCTIONS OF WRPC ..................................................................................................................................................... 11
CHAPTER 2 ................................................................................................................................................................................................. 13
2.1 PREAMBLE ........................................................................................................................................................................... 13
2.2 NAPHTHA HYDROTREATING UNIT .......................................................................................................................... 13
2.2.1 FEED PREHEATING ..................................................................................................................................................... 14
2.2.2 HEATING .......................................................................................................................................................................... 15
2.2.3 REACTION SECTION ................................................................................................................................................... 17
2.2.4 COOLING........................................................................................................................................................................... 17
2.2.5 FLASHING ........................................................................................................................................................................ 18
2.2.6 STRIPPING ....................................................................................................................................................................... 19
2.3 CATALYTIC REFORMING UNIT ................................................................................................................................... 20
2.3.1 THE REACTION ............................................................................................................................................................. 21
2.3.2 REACTORS ....................................................................................................................................................................... 26
2.3.3 HEATING .......................................................................................................................................................................... 27
2.3.4 Process variable and control consideration ...................................................................................................... 28
2.4 KEROSENE HYDROTREATING UNIT (KHU) .......................................................................................................... 29
2.5 PROCESS EQUIPMENTS DESCRIPTION ................................................................................................................... 29
2.5.1 Fractionating/distillation Column .............................................................................................................................. 29
2.5.2 Pumps ...................................................................................................................................................................................... 31

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2.5.3 Compressors ......................................................................................................................................................................... 32

2.5.4 Heat exchangers.................................................................................................................................................................. 33
2.5.5 Air coolers ............................................................................................................................................................................. 35
2.5.6 Pneumatic control valves ............................................................................................................................................... 36
2.5.7 Separator Drum ............................................................................................................................................................... 38
2.6 OPERATIONAL PROBLEMS IN THE PLANT AND THEIR SOLUTIONS ....................................................... 38
2.7 HAZARDS IN THE PLANT ............................................................................................................................................... 41
2.8 SAFETY IN THE PLANT ................................................................................................................................................... 43
2.9 OPERATIONS PERFORMED IN THE PLANT ........................................................................................................... 43
2.9.1 Soot blowing ......................................................................................................................................................................... 43
2.9.2 Chlorine injection ............................................................................................................................................................. 44
2.9.3 Phosphate injection ........................................................................................................................................................ 44
2.9.4 Regeneration ..................................................................................................................................................................... 44
CHAPTER 3 ................................................................................................................................................................................................. 45
3.1 PROBLEMS ENCOUNTERED DURING THE SIWES PROGRAM ...................................................................... 45
3.2 RELEVANCE OF THE SIWES PROGRAMME TO THE STUDENTS COURSE OF STUDY........................ 45
CHAPTER 4 ................................................................................................................................................................................................. 47
4.1 CONCLUSIONS AND GENERAL APPRAISAL OF THE PROGRAMME ............................................................ 47
4.2 RECOMMENDATIONS ON WAYS OF IMPROVING THESIWES PROGRAMME ......................................... 47
4.3 ADVICE FOR FUTURE PARTICIPANTS ..................................................................................................................... 48
4.4 ADVICE FOR SIWES MANAGERS................................................................................................................................. 48
4.5 CONCLUSION ....................................................................................................................................................................... 48
5 REFERENCES ................................................................................................................................................................................... 49
6 APPENDICES .................................................................................................................................................................................... 50

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LIST OF FIGURES
Figure 1.1: The Entrance of WRPC .................................................................................................................................................... 7
Figure 1.2: Organogram of WRPC ...................................................................................................................................................... 8
Figure 1.3: Organogram of Production Department ................................................................................................................. 9
Figure 2.1: Block Diagram of Reforming Plant ........................................................................................................................... 13
Figure 2.2: Block Diagram of NHU ................................................................................................................................................... 14
Figure 2.3: Cabin (left) and cylindrical (right) heater types ................................................................................................ 16
Figure 2.4: Block diagram of CRU process sections ................................................................................................................. 21
Figure 2.5: Process flow diagram of a semi-regenerative catalytic reformer unit..................................................... 23
Figure 2.6: Radial flow fixed bed reactors in actual reforming unit ................................................................................. 27
Figure 2.7: A typical distillation column ....................................................................................................................................... 30
Figure 2.8: Interiors of a fractionating column .......................................................................................................................... 31
Figure 2.9: Naphtha hydrotreating unit feed pump ................................................................................................................. 32
Figure 2.10: Make up hydrogen gas compressor ...................................................................................................................... 33
Figure 2.11: Heat Exchanger .............................................................................................................................................................. 34
Figure 2.12: Tube Bundle .................................................................................................................................................................... 35
Figure 2.13: Air Coolers ........................................................................................................................................................................ 36
Figure 2.14: Pneumatic Control Valve ........................................................................................................................................... 37
Figure 2.15: Horizontal Separator Drum ...................................................................................................................................... 38
Figure 2.16: Fire Triangle .................................................................................................................................................................... 42

LIST OF TABLES
Table 1.1: WRPC DESIGN PRODUCT SCALE 11
Table 2.1: NHU COMBINED FEED PREAHEATER 15
Table 2.2: REACTOR FEED HEATER PROPERTIES 16
Table 2.3: HYDRODESULPHURISATION REACTOR 17
Table 2.4: NHU PREFLASH COOLERS 18
Table 2.5: COOLED EFFLUENT H.P SEPARATOR 18
Table 2.6: H.P SEPARATOR EFFLUENT COOLER 19
Table 2.7: COOLED EFFLENT L.P SEPARATOR 19
Table 2.8: NHU STRIPPER COLUMN 19
Table 2.9: NHU STRIPPER REFLUX DRUM 20

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CHAPTER 1

1 INTRODUCTION

1.1. HISTORY OF SIWES

Body Normal (Font Name: Cambria, Font Size: 10).

The students SIWES program is a skill-acquisition program designed for 300 Level and 400 Level students
of most tertiary institutions as a complementary program to the theoretical education and laboratory
practices engaged in by students in tertiary institutions, which by industrial standard are inadequate to
serve the practical needs of the industries. The practices are idealistic and therefore necessitate that the
student be exposed to actual life practice, which is a far departure from academic institutional class and
laboratory practice.

The official Gazette of the Federal Republic of Nigeria made it clear that, the Supreme Military Council then
headed by General Yakubu Gowon in the year 1972 promulgated decree No.47 to indigenize the Nigeria
Economic Sector. On the 31st of March 1974, the decree came into effect with its core aim of reducing the
dominance of foreigners in the Nigerian economy, and accompanied by a systematic integration of locally
oriented skilled manpower into the economy.

The indigenization decree established many bodies which were charged with different responsibilities to
make the nations dream a reality. Among them include:

i. Industrial Training Fund (ITF)

ii. Centre for Management Development (CMD)

iii. Administrative Staff College of Nigeria (ASCON).

The Industrial Training Fund (ITF) was charged with the responsibility of training low and middle level
manpower for sustainable industrialization.

However, when the Federal Government observed that the training of students who are still in school
would be easier and cheaper, and that such training would make them more competent to assume any
responsibility to their related field of study, a scheme known as Students Industrial Work Experience
Scheme was established under ITF. This body was mandated to liaise with all the relevant agencies like
National Universities Commission (NUC), National Board for Technical Education (NBTE) to ensure proper
training of undergraduate students. The Students Industrial Work Experience Scheme (SIWES) was
established in 1974, since the inception of SIWES, it has been a partial fulfillment of the academic program.
SIWES is devised by National University Commission (NUC) as a skill training program that will bridge the

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long gap that demarcates theory from practical in science and technology and other related courses in
Nigeria Universities.

1.2. AIMS AND OBJECTIVES OF SIWES

The course is aimed at:

Building the students ability to work with equipment they do not have access to in school.

Providing an opportunity for students to apply the theoretical knowledge acquired in the
classroom to a real practical work situation.

Preparing the student against the real challenge they would encounter in their field of
specialization after graduation.

The industries/organizations get involved in training the manpower they need; thereby preparing
the trainee for employment opportunity after graduation.

Participation in Industrial Training is a well-known educational strategy. Classroom studies are integrated
with learning through hands-on work experiences in a field related to the students academic major and
career goals. Successful internships foster an experiential learning process that not only promotes career
preparation but provides opportunities for learners to develop skills necessary to become leaders in their
chosen professions.

Participation in SIWES has become a necessary pre-condition for the award of Diploma and Degree
certificates in specific disciplines in most institutions of higher learning in the country, in accordance with
the education policy of government.

Operators: The ITF; the coordinating agencies (NUC, NCCE, NBTE), employers of labor and the
institutions.

Funding: The Federal Government of Nigeria

Beneficiaries: Undergraduate students of the following: Agriculture, Engineering, Technology,

environmental, science, education, medical science and pure and applied sciences.

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1.3. THE COMPANY

In fulfillment of the SIWES program, I was attached to WARRI REFINING AND PETROCHEMICAL COMPANY
LIMITED.EKPAN- WARRI,DELTA STATE.

Figure 1.1: The Entrance of WRPC

Warri refining and petrochemical company is a leading company in the oil and gas sector in Nigeria. The
period of my industrial attachment was from August 2011 to February 2012.

The naphtha hydro-treating and catalytic reforming unit under the production department is the section I
was deployed to, for the duration of my attachment and as hence experienced the production of reformate,
treated naphtha, gasoline(petrol) and other by-products such as hydrogen gas, propane, butane and other
light hydrocarbon ends e. t. c. Also, the unit produces medium pressure steam used to drive steam turbine
pumps and compressors.

1.4. HISTORY OF THE ORGANIZATION

Nigerian National Petroleum Corporation (NNPC) was formed in 1977 through the merger of some of the
departments of the ministry of petroleum resources and the old Nigerian National Oil Corporation (NNOC).
In 1978, the corporation was commercialized into twelve strategic business units, the Warri Refining and
Petrochemical Company (WRPC) being one of them. The refinery commissioned in 1978 by LT. COL.
OLUSEGUN OBASANJO was built and designed by Snamprogetti, an Italian company with an initial capacity

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of 100,000 barrels per stream day of crude oil. It was de-bottle necked in 1987 to 125,000 barrels per
stream day (17,000metric tonnes per day).

The fuel plants were designed to process the CHEVRONS ESCRAVOS crude oil (sweet crude) and SHELLS
UGHELLI QUALITY CONTROL CENTRE (UQCC) crude oil (sour crude).

The petrochemical plants (polypropylene and carbon black) which were built to optimize the refinery
were commissioned in March 1988. An HYDRO-FLOURIC alkylation unit was also added to the refinery the
same year.

1.5. ORGANIZATIONAL CHART

Figure 1.2: Organogram of WRPC

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The department where I was deployed to:

Figure 1.3: Organogram of Production Department

1.6. BRIEF DESCRIPTION OF THE UNITS

Atmospheric Distillation Unit: This unit utilizes atmospheric pressure in the distillation of crude to
produce gasoline, naphtha kerosene, residue (bottom) and other fractions.

Vacuum Distillation Unit: This unit of the refining crude oil utilizes negative pressure to distil
atmosphere bottoms into gas oils and asphalt.

Desalter Unit: Washes out salt from the crude oil before it enters the atmosphere distillation unit.

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Kerosene Hydro-treating Unit: The purpose of this unit is to reduce the sulphur and nitrogen content of
the feed and to improve combustion characteristics of transportation fuels.

Naphtha Hydro-treating: Utilizes a cobalt molybdenum catalyst to remove metallic and non metallic
impurities found in the reformer feed.

Catalytic Reforming Unit: This unit is used to convert naphtha boiling range molecules into higher octane
reformate. Reformates has a higher content of aromatics and cyclic hydrocarbons. It also generates the
hydrogen utilized in naphtha hydro treating unit to remove impurities in the reformer feed.

Fluid Catalytic Cracking Unit: The basic purpose of this plant in the refinery is to convert heavy gas oil
which is of less market value into lighter, more valuable hydrocarbons. As the name implies, it uses a fine
powdery catalysts which under the action of fluidization medium such as air, hydrocarbon vapor or steam
behaves like a liquid. The unit is designed to process 26,000bpsd of gas oil feedstock into high valued
products like gasoline and LPG.

HF-Alkylation Unit: This is a process unit used to convert light olefins (e. g propylene, butylenes)
produced in catalytic crackers into a more highly valued gasoline component. Alkylate is one of the best
gasoline blending components produced in the refinery because of its high octane rating and lower vapor
pressure. It is usually referred to as a five star gasoline.

Waste Water Unit: This unit is involved in both collection and treatment of sour water and sludge
received from other units using treatment system like the API separator, dissolved air floatation, activation
sludge bioreactors and some other methods to make such water suitable for re-use or disposal.

Polypropylene Plant: Polypropylene is a thermoplastic polymer obtained by linking together many

molecules of propylene (-CH2CH2CH2-) a monomer. The monomer is collected in pressure vessels purified
and polymerized to produce a homo-polymer.

A blend on ethylene could be added in a secondary reactor to obtain a co-polymer which has enhanced
properties. The PP plant in WRPC is designed to produce 35,000 MT per year of Polypropylene pellets.

Carbon Black Plant: This plant is designed to produce 18,000 Metric-tonnes per day and is capable of
producing several grades of hard black. The plant is based on the Philips technology of regulated
incomplete combustion of decanted oil in horizontal tubular reactor. Carbon black is made of 90-97% very
fine elemental carbon particles. The remaining are organic compounds (carboxylic, phenols,
hydroquinone, lactones groups) strongly absorbed or chemically bounded to the surface layers. The
particle sizes as well as the non-carbon percentage vary in accordance with the different production
methods. Carbon black is used in the manufacture of inks, paints, conveyor belts, foot wears, and other
commodities.

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Auxiliary Units: These units are designed and built to provide various input material and services to the
processing units. They are not involved in the direct conversion of crude (raw material) to finished
products. They include:

Power Plant and Utilities

Water Treatment Plant
Nitrogen Plant
Compressed Air System
Electrical and Maintenance Workshop
Caustic Unit

Merox Treatment Plant

Oil Movement
Fire Safety and Environment
Engineering and Technical Service Department
Product Program Quality Control

At maximum design capacity, the refinery is configured to produce these products at the following rates:

Table 1.1: WRPC DESIGN PRODUCT SCALE

PRODUCTS METRIC TON/DAY LITRES

PROPANE 187 366,666

BUTANE 459 791,379

TOTAL PMS 5,015 6,598,684

KEROSENE 2,380 2,902,439

AGO 4,522 5,258,139

TOTAL FUEL OIL 3,808 4,094,623

1.7. FUNCTIONS OF WRPC

WRPC is primarily involved in the processing of crude oil into finished and semi-finished products. Its
products are sold in the Nigerian local market as well as overseas. The high quality of its products favors
her significantly in both local and foreign markets.

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The marketable products from the facilities are:

Liquefied Petroleum Gas(cooking gas/refrigerants)

Premium Motor Spirit(Petrol)

Kerosene(Domestic/Aviation)

Automotive Gas Oil(Diesel)

Fuel Oil

Polypropylene Pellets (Nipolene)

Carbon Black Pellets.

E.t.c

WRPC also create opportunities for students and young school leavers to gain industrial knowledge by
giving them placement for SIWES and NYSC programs respectively.

Research, human resource development and capacity building are performed by the company. These
functions are achieved through equipped library, sponsoring its staff to local and foreign training and
seminars and installation of modem laboratory facilities.

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CHAPTER 2

2.1 PREAMBLE
The reforming unit is quite a collection of process units. However the Process description can be divided
into 3 basic sub units namely:

Naphtha Hydrotreating Unit (unit 11)

Catalytic Reforming Unit (unit 12)
Kerosene Hydrotreating Unit (unit 13).

The CRU and NHU are both designed to process 2035.9 Metric Tons per stream day or 16,600 bpsd of
Heavy Naphtha. The installed capacity of the KHU is 8,500 bpsd.

These basic Units shall be discussed into sections as regards this chapter.

Figure 2.1: Block Diagram of Reforming Plant

2.2 NAPHTHA HYDROTREATING UNIT

This is the most important unit in the reforming plant. It is also called naphtha hydro-desulphurization unit
because its primary function is the removal of sulphur and other metallic impurities (vanadium, iron, nickel)
present in the feed coming from topping.

To properly eliminate the impurities, the feed undergoes series of processes namely:

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Figure 2.2: Block Diagram of NHU

2.2.1 FEED PREHEATING

Normally, feed (Heavy Naphtha) is supplied directly from topping unit and balanced with the storage flow
(tank17 in the tank farm). The feed is charged to the unit by the feed pump 11-PM-01.

The Heavy Naphtha feed is then mixed with hydrogen rich make up gas coming from the reforming unit before
it is being sent to the preheater. The combined feed is preheated in a two parallel heat exchangers 11-E-01
A/B.

The purpose of the preheater is to pre-heat the combined feed to the required heater inlet temperature to
prevent frying before it is properly heated to a temperature of about 300 degree centigrade. The combined
feed enters the heat exchanger through the inlet of the shell side and passes through the tube bundles before
finally leaving through the outlet of the shell side. Each heat exchanger contains hot heavy naphtha (HN) with
slurry respectively which helps to heat up the feed to about 250c-260c before it enters the heater.

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Table 0.1: NHU COMBINED FEED PREAHEATER

EXCHANGER TUBE SHELL

11-E-01 A/B Reactor Effluent Combined Feed

2.2.2 HEATING
The heater in the Naphtha Hydrotreating Unit is a cabin/cathedral heater (11-H-01) which operates by natural
draft system which is adjusted by a manual stack damper for the regulation of air into the heater chamber. The
preheated feed enters the furnace (heater) chamber. The heater is equipped with six burners which utilizes
fuel gas, fuel oil, pilot gas, and atomizing steam as its source of heat for proper combustion of the preheated
feed in the tubes. The feed first enters the tubes in the convection zone (top) of the furnace where it is heated
by the fuel gases before it enters the tubes in the radiation zone (bottom) for proper heating.

The purpose of the heating process is to properly heat up the feed to the required reactor inlet temperature of
about 300c.

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Figure 2.3: Cabin (left) and cylindrical (right) heater types

Table 0.2: REACTOR FEED HEATER PROPERTIES

Reactor Feed Heater 11-H-01

Design Pressure Kg/cm 30.4

Design Temperature Inlet C 293

Design Temperature Outlet C 370

Duty (MMKcal/h) 4.6

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2.2.3 REACTION SECTION

The type of reactor used in the Naphtha Hydrotreating Unit (unit 11) is a downflow fixed bed reactor (11-R-
01). The reactor utilizes a cobalt molybdenum catalyst for its reaction. The function of this reactor in the NHU
is to remove the impurities in the straight run Heavy Naphtha (i.e. to hydro- treat) by catalytically performing
some specific groups of chemical reactions namely: hydro-deoxygenation, hydro-desulphurization, and hydro-
denitrogenation.

1. R0H + H2 RH + H2O .................HYDRO-DEOXYGENATION

2. RSH + H2 RH + H2S ............HYDRO-DESULPHURIZATION

3. RNH + H2 RH + NH2 ...........HYDRO-DENITROGENATION

In the reactions, the non-metallic impurities {oxygen, sulphur, and nitrogen} are eliminated in the form of
water (H2O), hydrogen sulphide (H2S) and ammonia (NH2) respectively. The chemical reaction takes place
at a temperature of 300c

Table 0.3: HYDRODESULPHURISATION REACTOR

Pretreater Reactor 11-R-01

Size Mm 2400/4620

Design Pressure Kg/cm 28.7 The product

enters
Design Temperature C 385 through the
top of the
reactor (inlet) where it gets in contact with the ceramic balls and the catalyst before leaving through the
bottom (outlet).The pressure in the reaction section is controlled by 11-PRC-1

2.2.4 COOLING

The cooling process is performed by three cooler heat exchangers. The purpose of the coolers is to reduce
the temperature of the reactor effluent up to the required inlet temperature for the high pressure
separator drum 11-D-02. Therefore, the reactor effluent is cooled in the heat exchanger 11-E-01, air cooler
11-A-01 and trim cooler 11-E-02.

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Table 0.4: NHU PREFLASH COOLERS

EXCHANGER TUBE SHELL

11-E-01 A/B Reactor Effluent Combined Feed

11-A-01 Reactor Effluent Air

11-E-02 Cooling Water Reactor Effluent

Firstly, the product from the reactor enters directly to 11-E-01, and then to 11-A-01 and finally gets cooled in
11-E-02.

2.2.5 FLASHING
Flashing in the Naphtha hydrotreating unit is done in the high pressure separator drum and the low pressure
separator drums respectively. The primary function of the high pressure separator drum is for the separation
of the liquid hydrocarbon from the hydrogen/hydrogen sulphide/ammonia gas combination. Also, the
function of the low pressure separator drum is for the separation of liquefied petroleum gases(LPG) prior to
sending the hydrocarbon liquids to fractionation.

Table 0.5: COOLED EFFLUENT H.P SEPARATOR

H.P. SEPARATOR 11-D-01

Design Pressure Kg/cm 24.3

Design Temperature C 55

Thus, the cooled effluent from the exchanger 11-E-02 is flashed in the HP separator drum. The level in the HP
separator drum is controlled by a level regulator and controller (11-LRC-1).After the level controlvalve, the
separator liquid is mixed with the vapour distillates from the stripper overhead drum (11-D-03) and the
reformer stabilizer overhead drum (12-D-03) so as to permit maximum recovery of C3 and C4 for LPG
production.

The combined vapour and liquid stream is then cooled in the water cooler (11-E-03) after which it is flashed
into the low pressure separator drum.

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Table 0.6: H.P SEPARATOR EFFLUENT COOLER

EXCHANGER TUBE SHELL

11-E-03 Cooling water Hydrocarbons

Table 0.7: COOLED EFFLENT L.P SEPARATOR

LP SEPARATOR 11-D-02

Design Pressure Kg/cm 14

Design Temperature C 55

The vapour phase is sent to fuel gas under pressure control (11-PRC-02) while the separator liquid is pumped
to the stripper column.

2.2.6 STRIPPING
The stripping process is performed in the fractionating column which utilizes the principle of distillation. The
purpose of the stripper 11-C-01is to remove Hydrogen Sulphide (H2S), Water (H2O), and Light hydrocarbon
ends from the treated naphtha before being sent to the reforming unit.

Table 0.8: NHU STRIPPER COLUMN

HYDROTREATER STRIPPER 11-C-O1

No of Trays 31

Design Pressure Kg/cm 16.9

Design Temperature bottom C 277

The feed flow rate to the stripper is controlled by a flow regulator and controller (11-FRC-2) in cascade with a
level regulator and controller (11-LRC-2) which controls the level on 11-D-02. The feed to the stripper is
preheated in a two parallel heat exchangers (11-E-04 A/B). Also the stripper bottoms are cooled by heat
exchange in 11-E-04 A/B and then sent as H2S free feed to the reforming unit.

Part of the treated naphtha is sent to storage. The amount of treated naphtha sent to storage tank is measured
and recorded by the totalizing flow meter 11-FT-51.

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It is desirable to maintain a constant feed flow rate to the Catalytic Reforming Unit to avoid perturbations on
the reactions. Therefore, the feed flow rate to the reforming unit is controlled by 12-FRC-1 and 12-FRC-2.

The stripper overhead vapoursare partially condensed in air cooler 11-A-02and trim cooler 11-E-05and finally
separated into liquid and vapour phases in the reflux drum 11-D-03.

Table 0.9: NHU STRIPPER REFLUX DRUM

REFLUX DRUM 11-D-03

Design Pressure Kg/cm 14

Design Temperature C 55

The Vapour phase from 11-D-03 is recycled for LPG recovery(or is sent to fuel gas system) .The Liquid phase is
sent partially as reflux to the top of the stripper column, it is also sent partially as LPG to the gas plant unit 14.
The quantity of LPG is measured and totalized by flow meter 11-FT-52. The water eventually entrained in the
naphtha charged to the pretreating unit is separated by decantation in 11-D-03 and removed from the boot
attached to the stripper reflux drum and sent to Sour Water Stripper 202-C-01.

Stripper column most important operating variables are: temperature profile along the column, pressure and
products composition. These variables directly influence each other and depend on other variables such as
reflux rate and reboiler temperature.

2.3 CATALYTIC REFORMING UNIT

Catalytic reforming is a chemical process used to convert petroleum refinery naphtha, typically having low
octane ratings, into high-octane liquid products called reformates which are components of high-octane
gasoline (also known as petrol). Basically, the process re-arranges or re-structures the hydrocarbon molecules
in the naphtha feedstock as well as breaking some of the molecules into smaller molecules. The overall effect is
that the product reformate contains hydrocarbons with more complex molecular shapes having higher octane
values than the hydrocarbons in the naphtha feedstock. In so doing, the process separates hydrogen atoms
from the hydrocarbon molecules and produces very significant amounts of by-product hydrogen gas for use in
a number of the other processes involved in a modern petroleum refinery. Other by-products are small
amounts of methane, ethane, propane, and butanes.

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Figure 2.4: Block diagram of CRU process sections

2.3.1 THE REACTION

There are many chemical reactions that occur in the catalytic reforming process, all of which occur in the
presence of a catalyst and a high partial pressure of hydrogen. Depending upon the type or version of
catalytic reforming used as well as the desired reaction severity, the reaction conditions range from
temperatures of about 495 to 525 C and from pressures of about 5 to 45 atm.

The commonly used catalytic reforming catalysts contain noble metals such as platinum and/or rhenium,
which are very susceptible to poisoningthe nitrogen compounds.

The four major catalytic reforming reactions are:

1: The dehydrogenation of naphthenes to convert them into aromatics as exemplified in the conversion
methylcyclohexane (a naphthene) to toluene (an aromatic), as shown below:

2: The isomerisation of normal paraffin to isoparaffinsas exemplified in the conversion of normal octane to
2, 5-Dimethylhexane (an isoparaffin), as shown below:

3: The dehydrogenation and aromatization of paraffins to aromatics (commonly called

dehydrocyclization) as exemplified in the conversion of normal heptanes to toluene, as shown below:

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4: The hydrocracking of paraffins into smaller molecules as exemplified by the cracking of normal
heptanes into isopentane and ethane, as shown below:

The hydrocracking of paraffins is the only one of the above four major reforming reactions that consumes
hydrogen. The isomerisation of normal paraffins does not consume or produce hydrogen. However, both
the dehydrogenation of naphthenes and the dehydrocyclization of paraffins produce hydrogen. The
overall net production of hydrogen in the catalytic reforming of petroleum naphthas ranges from about 50
to 200 cubic meters of hydrogen gas (at 0 C and 1 atm) per cubic meter of liquid naphtha feedstock.

The process flow diagram below depicts a typical semi-regenerative catalytic reforming unit.

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Figure 2.5: Process flow diagram of a semi-regenerative catalytic reformer unit

The liquid feed (at the bottom left in the diagram) is pumped up to the reaction pressure (5 to 45 atm) and
is joined by a stream of hydrogen-rich recycle gas. The resulting liquid-gas mixture is preheated by flowing
through a heat exchanger. The preheated feed mixture is then totally vaporized and heated to the reaction
temperature (495 to 520 C) before the vaporized reactants enter the first reactor. As the vaporized
reactants flow through the fixed bed of catalyst in the reactor, the major reaction is the dehydrogenation of
naphthenes, to aromatics (as described earlier herein) which is highly endothermic and results in a large
temperature decrease between the inlet and outlet of the reactor. To maintain the required reaction
temperature and the rate of reaction, the vaporized stream is reheated in the second fired heater before it
flows through the second reactor. The temperature again decreases across the second reactor and the
vaporized stream must again be reheated in the third fired heater before it flows through the third reactor.

As the vaporized stream proceeds through the three reactors, the reaction rates decrease and the reactors
therefore become larger. At the same time, the amount of reheat required between the reactors becomes
smaller. Usually, three reactors are all that is required to provide the desired performance of the catalytic
reforming unit.

Some installations use three separate fired heaters as shown in the schematic diagram and some
installations use a single fired heater with three separate heating coils.

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The hot reaction products from the third reactor are partially cooled by flowing through the heat
exchanger where the feed to the first reactor is preheated and then flow through a water-cooled heat
exchanger before flowing through the pressure controller (PC) into the gas separator.

Most of the hydrogen-rich gas from the gas separator vessel returns to the suction of the recycle hydrogen
gas compressor and the net production of hydrogen-rich gas from the reforming reactions is exported for
use in the other refinery processes that consume hydrogen (such as hydrodesulphurisation units and/or a

The liquid from the gas separator vessel is routed into a fractionating column commonly called a stabilizer.
The overhead off gas product from the stabilizer contains the by product methane, ethane, propane and
butane gases produced by the hydro cracking reactions as explained in the above discussion of the reaction
chemistry of a catalytic reformer, and it may also contain some small amount of hydrogen. That off gas is
routed to the refinery's central gas processing plant for removal and recovery of propane and butane. The
residual gas after such processing becomes part of the refinery's fuel gas system.

The bottoms product from the stabilizer is the high-octane liquid reformate that will become a component
of the refinery's product gasoline.The reactions are governed by kinetics and thermodynamic rules which
means that they tend towards a thermodynamic equilibrium at varying rates.Usually, the optimum
equilibrium that can be obtained will depend upon the operating conditions that are temperature,
pressure, e.t.c. The reaction rates with which this equilibrium is reached is mainly a function of the quality
and the properties of the catalyst.The extent to which a catalyst favours one or the other reaction and thus
influences the final equilibrium is called the selectivity.

The chemical reactions described above are those that the reforming catalyst favours with respect to
other.Due to these decreasing rates, it is possible to localize the reaction in the following manner:

1st reactor
o Dehydrogenation
o Isomerisation
2nd reactor
o Dehydrogenation
o Isomerisation
o Hydrocracking
o Dehydrocyclisation
3rd reactor
o Isomerisation

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o Hydrocracking
o Dehydrocyclisation
4th reactor
o Hydrocracking
o Dehydrocyclisation

In every reactor, there is always a catalyst which helps to speed up the reaction. Most catalytic reforming
catalysts contain platinum or rhenium on a silica or silica-alumina support base, and some contain both
platinum and rhenium. Fresh catalyst ischlorided (chlorinated) prior to use.

The noble metals (platinum and rhenium) are considered to be catalytic sites for the dehydrogenation
reactions and the chlorinated alumina provides the acid sites needed for isomerisation, cyclization and
hydrocracking reactions.

The activity (i.e., effectiveness) of the catalyst in a semi-regenerative catalytic reformer is reduced over
time during operation bycarbonaceous coke deposition and chloride loss. The activity of the catalyst can be
periodically regenerated or restored by in situ high temperature oxidation of the coke followed by
chlorination. As stated earlier herein, semi-regenerative catalytic reformers are regenerated about once
per 6 to 24 months.

Simplified description of the flow diagram:

Treated naphtha coming hot from the bottom of hydrotreater stripper 11-C-01 is directly charged to the
reforming unit through pump 12-P-01 A/B.

The feed is then mixed with recycle gas been compressed by compressor 12-K-01.

The combined feed is then preheated in12-E-01 A/B.

The combined feed from the heat exchangers is sent to the heater 12-H-06 and then it is sent to the 12-H-
01.

After heating, the combined feed enters the first reactor 12-R-01.

Due to the endothermicity of the reactions each reactor effluent must be heated by means of 3 fired
heaters 12-H-02, 12-H-03 and 12-H-03 and 12-H-04 situation before 12-R-02, 12-R-03 and 12-R-04
respectively.

The effluent from the fourth reactor is cooled through 12-E-01 A/B, it is further cooled in air cooler 12-A-
01 and trim cooler 12-E-02 before it is flashed in the first separator 12-D-01.

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The major part of the vapour from reforming L.P. separator 12-D-01 is split into two streams which are
compressed by compressor 12-K-01 and 12-K-02 A/B/C respectively.

The rest of the vapour is purged to fuel gas.

As mentioned earlier one stream of the vapour phase from 12-D-01 is compressed by compressor 12-K-01
and sent, as recycle gas, to the reaction section.

The other stream passes through the K.O drum 12-D-04 and is compressed by 12-K-02 A/B/C and mixed
with the liquid phase from 12-D-01 which is pumped by 12-P-02 A/B to the required pressure.

The combined flow is cooled the trim cooler 12-E-03 and flashed in the H.P. separator drum 12-D-02.The
vapour phase from 12-D-O2 is sent to battery limit to kero hydrogenation (unit 13) and to make up for
naphtha hydrotreating (unit 11), while the liquid phase is sent to the stabilizer column.

Before entering the stabilizer column, the field is pre-heated in exchanger 12-E-04 A/B by the stabilizer
bottom product.

2.3.2 REACTORS
A reactor is a process vessel in which chemical reactions (catalyzed or non-catalyzed) the place during a
chemical conversion type of process. The four reactors installed in actual reforming unit are radial-flow-
fixed bed reactor. This reactor is a variance of the down flow fixed-bed reactor.

Again, the feedstock enters the top of the reactor but instead of flowing downward through the catalyst
bed, the feedstock is encouraged to flow through the bed in a radial direction and then out through the bed
in a radial direction and then out through the base of the reactor.

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Figure 2.6: Radial flow fixed bed reactors in actual reforming unit

2.3.3 HEATING
Description

After passage through 12-E-01 A/B the feed is sent to the feed preheated 12-H-06 and then it is sent to
the first reforming heater 12-H-01 before entering 12-R-01(first reactor).

Due to the endothermicity of the reactions each reactor effluent must be heated by means of 3 fired
heaters 12-H-02,12-H-03,12-H-04 situated before 12-R-02,12-R-03 and 12-R-04 respectively.

The required temperature of each reactor inlet is controlled by TRC situated at the outlet of each heater.

The TRCs reset the amount of fuel to each heater.

12-H-06 description

The combined feed is controlled into the furnace 12-H-06 radiant zone. (Six burners)

12-H-01 Description

The combined feed is introduced into the furnace 12-H-01 radiant zone.(twelve burner

12-H-02 description

The effluent from the first reactor is introduced into the furnace 12-H-02 radiant zone (twelve burners)

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12-H-03 description

The effluent from the second reactor is introduced into the furnace 12-H-03 radiant zone. (Eighteen
burners)

12-H-04 description

The effluent from the third reactor is introduced into the furnace 12-H-04 radiant zone (Six burners).

It should be noted that in each of the heaters thermocouple are installed to show:

1. Skin point of the tubes in the radiant zone

2. Flue gas temperature in the convective zone and stack and oxygen analyzer recorder is installed in the
convective zone.

The burners are of mixed type, fuel gas, fuel oil and atomized steam.

2.3.4 Process variable and control consideration

Process variables in fixed bed reactor are:

1. Reactor temperature
2. Reactor pressure
3. Reactor space velocity
4. Hydrogen / hydrocarbons mole ratio
5. Feed composition
6. Catalyst activity.

All of these variables affect the product quality and the economics of operations. The first three of these
variables, listed in order of the effect on product quality, are usually under the direct control of the unit
operator, as is possible for the particular unit and type of operation. The fourth may be controlled by the
operator in some cases. It is frequently fixed during the design of the plant on the basis of a known charger
stock and severity of operations, or is fixed during plant operation by other considerations as discussed
later.

The fifth variable, charge stock composition, is normally not at the discretion of the operator. This is true
especially when the charge stock is a single stream from an upstream limit. If streams from multiple
sources are charged, the operator has some range of control over the final charge stock composition.
Catalyst activity, the last variable depends upon the catalyst and the previous catalyst history. Severity is a
combination of temperature, pressure and space velocity.

Higher severity is accomplished by one or more of the following:

1. Increasing reactor temperature

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2. Decreasing reactor pressure

3. Decreasing reactor space velocity

As in all process, control of reformers for desired results is achieved by control of the process variables.
Reactor temperature is probably the most important variable in the control of catalyst reformer. In a
particular unit, pressure and space velocity are usually fixed by basic operational considerations as
discussed later. This leaves temperature as the controlling factor in severity control. Reactor temperature
is controlled at the reactor inlet (furnace outlet).

2.4 KEROSENE HYDROTREATING UNIT (KHU)

Straight-run Kerosene or Household Kerosene obtained from the crude distillation unit (CDU) is the feedstock
to this unit. Straight run kerosene streams may not meet specifications for jet-fuel. Hence, this unit converts
straight run kerosene into aviation kerosene (jet fuel) by using mild hydro-dearomatization (HDA) to convert
some aromatic compounds into cleaner-burning naphthenes thereby improving its combustion
characteristics. Fixed bed catalytic reactors are employed in the presence of hydrogen for the removal of
impurities and smoke point improvement. The general operating principles are similar to those of NHU and
CRU. The installed capacity of this unit is 8,500 bpsd.

2.5 PROCESS EQUIPMENTS DESCRIPTION

2.5.1 Fractionating/distillation Column
Fractional Distillation columns in the refinery are usually operated at a steady state. Unless disturbed by
changes in the feed, heat, ambient temperature, or condensing. The amount of feed being added normally
equals the amount of product being removed.

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Figure 2.7: A typical distillation column

It should be noted that the amount of heat entering the column from the reboiler and with the feed must equal
the amount of heat removed by the condenser and with the products. The heat (temperature) entering the
column is a crucial operating parameter, addition of excess or

insufficient heat to the column can lead to entrainment, flooding e.t.c. The fractionating column usually
separates a feed stream into one distillate fraction. However, the columns have outlets at intervals up the
column so that multiple products having different boiling ranges may be withdrawn from the column distilling
a multi-component feed stream. The "lightest" products with the lowest boiling points exit from the top of the
columns and the "heaviest" products with the highest boiling points exit from the bottom.

Fractionating columns in the refining plants uses external reflux to achieve better separation of products
thereby maintaining the temperature profile at the top of the column. Reflux refers to the condensed overhead

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liquid product that returns to the upper part of the column (after the overhead vapour has been condensed by
a heat exchanger and separated in a reflux) drum.

Inside the column, the downflowing reflux liquid (downcomers) provides cooling and condensation of
upflowing vapours thereby increasing the efficacy of the distillation tower. Bubble cap "trays" are one of the
types of physical devices, which are used to provide good contact between the upflowing vapors and the
downflowing liquids inside the fractionating column. The efficiency of a tray or plate is typically lower than
that of a theoretical 100% efficient equilibrium stage. Hence, a fractionating column almost always needs
more actual, physical trays than the required number of theoretical stages.

Figure 2.8: Interiors of a fractionating column

2.5.2 Pumps
These are mechanical devices used to transport liquids to a required destination especially through long
distances. They do so by increasing the pressure of such liquids. Pumps are composed of various parts
such as the suction line, discharge line, pump casing, impellers (rotor), drive shaft, etc. The pumps in the
reforming plant are either driven by an electric motor or a steam turbine. Attached to the discharge line is
a check valve to prevent back flow of fluids. PM/PT is the acronym for pumps in the plant meaning pump
motor/pump turbine respectively, depending on it driving force. There are of various types namely:

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centrifugal pumps, reciprocating pumps, submersible pumps, positive displacement pumps, screw pumps
etc.

However, WRPC reforming plant only utilizes the centrifugal and reciprocating pumps for its operations.

Figure 2.9: Naphtha hydrotreating unit feed pump

2.5.3 Compressors
Compressors are machines used for compressing air or other gases. There are two main types of compressor
in the reforming plant namely:

Centrifugal compressors which are dynamic machines that increase the pressure of a fluid (air or gas)
traversing it by applying inertia forces (acceleration turning) to the fluid. For example 12-K-02
A/B/C in the catalytic reforming unit (which compresses H 2 for recycling) and 112-K-01 in the
naphtha hydrotreating unit (for the hydrogen bottles in batches).

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Figure 2.10: Make up hydrogen gas compressor

Reciprocating compressors which achieve the desired compression of gases by means of a piston
moving back and front in a cylinder. They are especially used to obtain very high pressures but
cannot reach high flow rates because of their low speed. For example 12-KT-01 in the catalytic
reforming unit (which also compresses H2 and sent as recycle gas to the reaction section).

2.5.4 Heat exchangers

Heat exchangers are equipment that is used in operations such as:

Cooling a liquid.
Heating a liquid.
Condensing a gas.
Evaporating a liquid.
Re-boiling a liquid.

For this reason, they could be referred to as:

a. Coolers.

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b. Heaters.
c. Condensers.
d. Evaporators.
e. Re-boilers.

Heat exchangers are usually divided into two sections (tube and shell).They use a conducting element which is
usually in the form of a tube or plate to separate two fluids such that one can transfer thermal energy to the
other without inter-mixing both fluids. The hotter products that needs to be cooled enters through the tube
inlet and leaves through the tube outlet, while the colder products that needs to be heated enters through the
shell inlet and leaves through the shell outlet of the heat exchanger.

Figure 2.11: Heat Exchanger

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Figure 2.12: Tube Bundle

These exchangers could be either of the following depending on the physical structure and function; tube and
shell type, fixed tube, floating head, kettle type and u-tube heat exchanger. The heat exchangers are equipped
with series of baffles that increases the residence time by delaying flow, thereby allowing for better
cooling/heating. Heat exchangers in the unit are assigned the acronym E. An example is 12-E-04.

2.5.5 Air coolers

This equipment is utilized to reduce the temperature of fluids in the units. It could also be called a heat
exchanger. The cooling is achieved by the action of atmospheric air being blown by the fan blades driven by
electric motors. The hot streams which are present in the air cooler fins, exchanges heat with the ambient air
temperature. Thereafter, the fluid flows out through a common discharge point called down comers manifold.
Air coolers are designated the acronym AM. For instance, 11-AM-02 and 12-AM-01 are good examples of air
coolers.

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Figure 2.13: Air Coolers

2.5.6 Pneumatic control valves

These are valves that are automatically controlled by pressurized instrument air. Control valves are used to
control process variables such as temperature, flow rate pressure and liquid level by fully/partially opening or
closing in response to signals received from controllers that compares asset point to a variable whose values
are provided by sensors that monitor changes in such conditions. Positioners are used to control the opening
and closing of the actuator based on pneumatic signal.

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Figure 2.14: Pneumatic Control Valve

Other valves found in the units are

Ball valves which are good for on/off control. They are usually installed along a water line.
Gate valves which are mainly used for isolation (i.e. to fully open or close). It is otherwise known for
on/off control.
Globe valves or throttling valves which is good for controlling and regulating flow.
Check valves or non-return valve which allows the fluid to flow only in one direction (0ne directional
valve). It is usually installed in the discharge line of pumps and compressors.
Plug valves for on/off control.
Needle valves installed along an instrument line.
Safety valve or pressure relief valve operated automatically at a set differential pressure to correct a
potentially dangerous situation, typically over-pressure.
Butterfly valve for control of gas flow.

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2.5.7 Separator Drum

Separation of petroleum products having different densities are carried out in drum separators. Most of these
drums are pressurized, while others are equipped with demisters which prevent the passage of liquids.
Separation of products into their constituent components occurs as a result of gravitational force. Hence, they
are sometimes called gravity settlers. Example includes the reflux drum 11-D-03.

Figure 2.15: Horizontal Separator Drum

2.6 OPERATIONAL PROBLEMS IN THE PLANT AND THEIR SOLUTIONS

a. Flooding

Flooding is the excessive accumulation of liquid inside the fractionating column which could be caused by;
low liquid flow rates (where most of the liquid on the tray is in the form of droplet), tray pressure drop,
liquid height on the tray, friction under the down comer and excessive feed charging, etc.

Solution

Flooding can be avoided by the use of control system to control process or operational variables.
Controllers to be used are:

o Level Recording Controller (LRC).

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o Flow rate Recording Controller (FRC).

o Pressure Recording Controller (PRC).
o Temperature Recording Controller (TRC).
b. Water problems

Water can cause severe operational problems in services which are not meant to handle it. Most problems
occur when the fractionating column separates water insoluble material such as hydrocarbons. If a slug of
cold water is suddenly dumped into a hot column containing hydrocarbons; the water will be vaporized.
This vapor is caused by the presence of the liquid phase simultaneously. The water phase will attempt to
exert is own vapor pressure and will therefore rapidly vaporize. Due to its low molecular weight, water
will expand to above 1000 to 2000 times the liquid volume upon vaporization close to atmospheric
pressure. This may generate a rapid and impulsive pressure surge. Such a pressure surge can dislodge or
damage trays, packing lines, support e t c.

Solution

o Overhead drums should be drained at intervals when control system fails.

o Process equipment (pumps) should be drained during streaming of the plant.

C. Dirty streams

The separator liquid(stripper feed) can be polluted by dirty vapor from flash zone. Dirty streams can be
caused by

Excessive water content which increases the vapor velocity in the flash zone of the column.
Insufficient reflux to keep the lower trays wet.
A low temperature at the heater (stripper reboiler) outlet causes insufficient vaporization in the
flash zone, and sufficient treated naphtha products may not be obtained.
Very high transfer temperature at the heater outlet causes the column to be subjected to excess
thermal duty input and increases the quantity of over flashed liquid.

Solution

Dirty stream can be minimized by ensuring that;

o Quality of stripper used must satisfy the operational conditions (temperature and pressure) to
attain optimal stripping operation.
o The amount of product removed from the column should be monitored by panel operators to
avoid rupturing of trays.

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o Temperature of feed from the outlet of the heater should be monitored. Then if any deviation from
its set point, other process variable should be altered to achieve the desired operational
temperature.
c. Cavitation
Cavitation is a phenomenon which occurs when there is an invasion of air (gas) in a pump thereby causing
an impeachment in the flow. This results to a jerk or an abnormal vibration (hammering) of the pump.
From continuum theory: fluid is said to be in a continuous phase devoid of void that is to say for a
moving fluid there ought to be no void spaces. Thus this phenomenon is likely to occur when bubbles of
vapor or pockets of air forms in the pump casing as a result of:
Insufficient feed
Overheating
Plugged suction filter
Sudden change in magnitude of the velocity of fluid
Misalignment of spacer coupling
Invasion of air into the liquid stream of the pump

Solution

Cavitation can be avoided by:

o Pump suction line always opened fully

o Cleaning of pump filter
o Prime and restart the pump
o Check product/ feed system
o Cooling of pump casing with cooling water when overheating occurs.

d. Surging

This has to do with a sudden/major increase in the noise of the compressor usually accompanied by a
powerful forward or backward movement. Surging can be caused by

Deformation of the gear shaft.

Excessive/Inconsistent gas flow rates.

Inadequate oil in the cylinder and frame of the compressor.

Malfunctioning of the air filters.

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Solution
o Gas flow rates should be kept constant by proper monitoring of the flow regulator and controller.

o Barring of gear should be properly conducted before starting up the compressors during shut
down

o Damaged air filters should be replaced immediately

o The Oil level in the frames and cylinders of the compressors should be properly monitored to
avoid shortage of oil.

o Pressure balance should always be monitored.

e. Incomplete Combustion

Incomplete combustion is a situation whereby coke deposited on the catalyst is burnt off with air and CO
(which constitutes a major health hazard to man) instead of CO2. Incomplete combustion is as a result of:

Insufficient supply of air for combustion reaction.

Insufficient circulation of nitrogen from the battery limit to the reactors.

Solution

o Air flow rates to the reactors should be increased.

o Combustion promoters should be introduced.

o Adequate circulation of nitrogen to the reactors should be ensured.

2.7 HAZARDS IN THE PLANT

These hazards can be grouped into:

1. Accidental Hazards

Slips and fall by floors made slippery by oil, grease, aqueous solutions and solvents.

Burns by contact with hot liquids or surfaces.

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Damage to eyes by splashing of irritating or corrosive liquids such as propylene di chloride

in the plant.

2. Physical Hazards

Exposure to excessive noise from mechanical equipment.

Hazards due to dangerous collision with process equipment.

Hazards due to mishandling of equipment such as valve key (openers), weight lifting
devices(such as cranes for lifting lube/seal oil drums) during tank loading.

3. Chemical Hazards

Chronic poisoning by inhalation or ingestion of any of the reforming chemicals used.

Latex allergy caused by the use of latex gloves

4. Explosive risk

In order for gas to ignite there must be an ignition source, typically a spark (or flame or hot surface) and
oxygen. For ignition to take place, the concentration of gas or vapor in air must be at a level such that the
fuel and oxygen can react chemically. The degree of the explosion depends on the fuel and its
concentration in the atmosphere. The relationship between fuel/air/ignition is illustrated in the fire
triangle below.

Figure 2.16: Fire Triangle

Therefore, explosion due to unsafe practices could occur leaving the plant personnel critically injured.

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2.8 SAFETY IN THE PLANT

The safety measures necessary to be observed in the reforming plant can never be over emphasized. Since
the production plant is an area highly exposed to hazards, plant operators are regularly checked by the
health safety and environment (HSE) officers to ensure that personnel in the plant are fully kitted with
their PPES (personal protective equipment) in order to maintain a safe working environment.

Some of the HSE guidelines in the reforming plant are as follows:

All operators in the plant should always put on their personal protective equipment (coverall, eye
goggles, ear muffs/plugs, nose mask, hand gloves, safety shoes and helmet) in order to guide
themselves from potential threats in the plant.

If an operation represents a potential safety or health threat, every effort should be made to plan a
safe way to complete the task in a safe manner.

Shortcuts in the plant is highly prohibited, therefore all procedures must be duly followed.

If an operator observes any unsafe or unprotected exposure which may pose a potential threat to
their safety and health, he or she must inform the chief operator or the superintendent
immediately for corrective measures.

If an operation cannot be performed safely, it should rather not be done.

2.9 OPERATIONS PERFORMED IN THE PLANT

Some operations performed occasionally in the reforming plant during the course of my attachment are
discussed below.

2.9.1 Soot blowing

Soot blowing is an operation performed with the use of a device called a Soot Blower which is used for
removing the soot (carbon deposit) that is deposited on the furnace tubes of the heaters during combustion.
Steam is normally used as a medium for blowing away the soot. When soot is deposited on the tubes, it then
acts as a heat insulator which is undesirable. The result is that less heat is transferred to the tubes to raise the

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temperature of the products in the tubes and more heat is wasted up the chimney stack. This leads to higher
fuel consumption and poor heating.

The soot blowers in the reforming unit are usually operated automatically from the control room with the aid
of the remotely controlled motors. It is sometimes operated manually if theres a failure on the part of the
controlling motors. The soot which is removed from the furnace tubes is blown out with the flue gases and
ejected into the outside air through the chimney stack.

2.9.2 Chlorine injection

Propylene di chloride (PDC) otherwise known as di-chloropropane is often pumped into the reforming
reactors in order to reduce the deactivation of the catalyst. An increase in the chlorine content of the catalyst is
immediately revealed by a corresponding increase in the activity on the catalyst. It is necessary to prevent the
increase in the concentration of chlorine from going over

those limits required to keep a correct balance between the metallic and acidic functions of the catalyst.
Beyond those limits, the liquid yield and useful life of the catalyst decrease to unacceptable values. The remedy
for hyperactivity of the catalyst consists of injecting small regulated doses of water in the feed.

Finally, for a perfect balance to be maintained, suitable proportions of water and the chlorinating agent (PDC)
is usually injected on the injection tanks (12-TK-13 and 12-TK-14) before being charged to the reforming
reactors.

2.9.3 Phosphate injection

To avoid scale deposit in the boiler system (for the production of steam), phosphate solution is injected into
the steam drum 12-D-10.The phosphate solution is prepared in tank 12-TK-02 by mixing the sodium
phosphate with demineralized water. The tank is equipped with an agitator 12-M-01in order to order to
ensure good mixing. The phosphate solution is drawn from the tank by means of the metering pumps 12-P-10
A/B and is sent to the steam drum 12-D-10.

The phosphate solution used in performing this operation is called tri-sodium phosphate with a chemical
formula of Na3PO4

2.9.4 Regeneration
The coke deposit acts on catalyst activity by reducing the surface of contact. During operation, carbon will
gradually accumulate on the catalyst. The aim of the regeneration operation is to remove this coke by
combustion and retain its initial activity.

The operation is performed with the unit out of service and consists of three phases which must be conducted
under rigidly controlled conditions:

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Combustion Phase with a controlled injection of air in circulating nitrogen.

Oxy-chlorination Phase with a controlled injection of carbon tetrachloride (CCL4) and air in
circulating nitrogen.
Sulphiding Phase with a controlled injection of Dimethyl disulphide (DMDS) in circulating hydrogen.
The sulphiding agent has its molecular formula as CH3SSCH3.
Chlorination Phase with a controlled injection of carbon tetrachloride (CCL4) in circulating
hydrogen.

CHAPTER 3

3.1 PROBLEMS ENCOUNTERED DURING THE SIWES PROGRAM

As ideal as the program is, the real world isnt as perfect as it seems, so also is the program itself. Some of
the problems encountered include the following;

1. The problem of attachment.

Students find it difficult to secure an appointment from any organization. At times most students even go
to where they never wanted instead of staying at home.

2. Problem of adaptation

One challenging experience I personally encountered was trying to adapt to the shift operation being
practiced at WRPC (production department). It was really challenging because we were been made to
work from 7a.m to 7p.m for two days and another 7p.m to 7a.m for another two days consecutively, we
were made to stay awake all night till the next morning.

3. Attitude towards IT students

The attitude of some company staffs towards IT students is something that can never be overemphasized,
as some staffs go as far as seeing the IT students as messengers (errand boys or girls) instead of teaching
and inculcating their professional experience on the students.

3.2 RELEVANCE OF THE SIWES PROGRAMME TO THE STUDENTS

COURSE OF STUDY
The program exposes the students to work methods and techniques in handling equipment and
machinery that may not be available in the university.
It provides students with the opportunity to apply theoretical knowledge to real work situation.

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It prepares students for the work situation they are likely to meet in the real world.
It provides an avenue for students in Nigerian universities to acquire industrial skills and
experience in their course of study.
It creates a platform for students to apply their theoretical knowledge in a practical form, thereby
bridging the gap between the academia and the industrial world.
It makes the transition from the university to real world easier and thus increases the students
contact for future job employment.
The program exposes students on how to co-operate with colleagues and staffs in their various
places of attachment and to be able to face real life problems.

Therefore, against these backdrops; I say thanks to the organizers of the program, my amiable and God
given lecturers and everyone involved in the success of the program.

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CHAPTER 4

4.1 CONCLUSIONS AND GENERAL APPRAISAL OF THE PROGRAMME

The SIWES program is a welcome development in the tertiary educational system. The program has helped
in bridging the gap between academic works and industrial experience i.e. the skills required to work in
the real world. It has also helped in creating some kind of self confidence in the participating students. The
program helps participants to discover their capabilities, strengths and weaknesses; thus making them to
be able to face the challenges of life after school.

During the course of my internship, I was privileged to work in the plant where I was acquainted with how
the most treasured commodity in Nigeria is produced and thats none other than the premium motor spirit
(PMS) popularly called petrol. I also got to understand that the same principles being practiced at WRPC is
similar to the principles being applied in any petroleum refinery in the world.

4.2 RECOMMENDATIONS ON WAYS OF IMPROVING THESIWES

PROGRAMME
I strongly suggest that the program be introduced right from the second year of study in all
science disciplines and third year in all Engineering disciplines. This will enable students to
be exposed to more than one industry and also increase the duration/frequency of the
program. Students will be equipped with the skills required for working in more than one
firm, thereby, increasing the level of employment opportunities for the students in the near
future.
It is necessary to sensitize staff of the various companies on how to relate to students by
helping them to get the needed knowledge.
It would be very important if the organizers of the SIWES program could sit with the
various companies and discuss the relevance of the program and to create more IT spaces.
Financial aids should be given to students in order to help them with feeding, transportation
etc.
All supervisors should visit every student in their various places of attachment.

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4.3 ADVICE FOR FUTURE PARTICIPANTS

They should take the seminar that will be held for them regarding the program very
seriously.
The program should be seen as a way of helping them to see what challenges await them in
the future.
They should be careful not to bring disrepute to the program by involving in indecent act.
The program itself should be taken seriously, even to the submission of IT application as
well as self-comportment within the organization as supervisors within the firm scrutinize
the students from these little things.
Lastly, they should take their studies seriously now as such theoretical knowledge gotten
in school serve as a foundation for them understanding the basis in real life performances.

4.4 ADVICE FOR SIWES MANAGERS

They should ensure that designated supervisors visit the students regularly and to see to
their activities.
In all humility I would like the SIWES managers to take into cognizance the fact that
sometimes abnormalities could occur in the system and this may lead to the organizational
supervisors to neglect the routine put forward by SIWES in signing log books and the
existence of students who complete the program unsupervised. My sincere hope is that
these issues would be adequately taken care of.
The managers should always encourage the students by seeing to their welfare.

4.5 CONCLUSION
In the course of the program, I came to terms with the different behavioral attitude of the working class.
The program got me a new view on how to handle operational issues with limited time. In all these, I
became confident of my ability to think independently.

SIWES has improved the practical skills of many students today. Indeed I am glad that I was part of it.
Personally speaking, it has improved my mental and practical capabilities in petroleum processing where
those theories learnt in class are being shown firsthand in the field. The objective created by the SIWES has
been organized to enable students have working experience not only the practical aspect of it but also how
to co-operate with members of staff and how to cope with real life problems. The overall benefits have
been immeasurable and invaluable. Therefore it should be encouraged and empowered immensely.

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5 REFERENCES
1. Fractional distillation - Wikipedia, the free encyclopaedia, 2010.
2. F.Y. El Kady, L.k. Mohammed, S.A. Shaban, Hydrotreatment of kerosene fraction to improve its
properties, Petroleum Refining Division. EPRI (July 2010) Vol. 2, 9-10.
3. Abdel-Aal, H.K. and Mohammed, A.: Petroleum and Gas Field Processing, Marcel-Dekker, Kuwait
(2003)
4. WRPC profile manual.
5. WRPC Reforming plant manual.

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6 APPENDICES

APPENDIX A

At the Naphtha Hydrotreating Unit

At the top of the Condensate Recovery Drum

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A group photo with other internship colleagues at the topping unit (CDU/ADU)

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APPENDIX B

During an operation at the top of the compressor section of the plant.

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