Facilities Details

1.Oil & Gas

Crude Unit

The crude unit intake capacity is 47,110 Barrels per day. Initially refinery was designed on Agha Jari crude, after modifications and removing the bottlenecks, capacity increased to 55000 Barrels per day. With that refinery becomes capable to process wide range of crude blends. The crude feed stock after desalting & heating at required temperature is fed to crude distillation tower where a portion of the crude lighter cut point is taken as single stream overhead product. Gas oil is produced as a side stream and residue is drawn from the tower bottom.

Desalter

Crude oil often contains impurities such as free water, inorganic salts, suspended solids and water-soluble trace metals. As a first step in the refining process, to reduce corrosion, plugging, fouling of equipment and to prevent poisoning of catalyst in processing units, these contaminants are removed by desalting. In desalting process, brine particles are coalesced with added wash water droplet and consequently separated by gravity.

Hydro Unit

Purpose

Remove the sulfur and other impurities to meet finished product specs and prepare feed stock for the reforming and Isomerization units. The hydro unit intake capacity is 2450 metric ton per day. A wide range of product streams are obtained from the crude unit. In most cases, the properties of these streams either as final products or as feed stock for further processing are adversely affected by components like Sulphur and Nitrogen.

BDG employs one of the vigorous methods of removal of Sulphur compounds known as Catalytic Hydrodesulphurization. Initially its capacity was 2450 metric ton per day, after modification and removing the bottlenecks capacity increased to 3000 metric ton per day. It reduces the sulfur, nitrogen and other oil based containments to make the products on specification. In hydrotreating the hydrocarbon streams are desulfurized by contacting the oil with a stationary catalyst (CoMo based) at high pressure and moderate temperature in the presence of hydrogen rich gas stream. The sulfur present in the oil is eliminated as hydrogen sulfide gas.

Plat former Unit

Purpose

– Improve the octane rating of straight run heavy naphtha

– Provide hydrogen for refinery hydrotreating units

The plat former unit intake capacity is 500 metric ton per day. Straight run gasoline obtained from crude unit cannot meet specification of motor gasoline because of its low octane. Platforming process is used to upgrade low octane number straight run naphtha to higher octane motor fuel blending components by catalytically promoting specific groups of chemical reactions.

BDG fixed bed semi regeneration Platforming Unit is process designed by UOP and after revamp, unit capacity is increased from 280 MTD to 500 MTD. The naphtha feed is mixed with re circulating Hydrogen rich gas to three reformer reactors where selective action of Bimetallic Catalyst upgrades the low octane feed to high octane reformate used for making gasoline. Hydrogen gas produced in platforming reaction used in hydrotreating unit.

Catalysts are regenerated in situ with the equipment installed after the completion of cycle length.

Isomerization Unit

Purpose

– Improve the octane rating of light Naphtha

As petroleum industry moved toward marketing fuels with lower lead levels, it became increasingly difficult to use light strait run Naphtha in the Gasoline pool. Conversion of low octane normal paraffins to their corresponding branched Isomers to increase their octane number is recognized as a logical & necessary step in a lead reduction program.

BDG Isomerization unit intake capacity is 522 metric ton per day. Light Naphtha received from crude unit having low octane number passes through platinum base catalyst convert into higher octane hydrocarbon (Isomerate) in the presence of hydrogen atmosphere. This is accomplished by the catalytic isomerization of pentanes & hexanes hydrocarbons.

Effluent Water Treatment Unit

Unit capacity 35 M3 per Hr

Effluent Water Treatment plant is a combined physico-chemical and aerobic biologic waste water treatment plant designed for treating process effluents prior to discharge from Refinery premises. Some of the sources of the waste water are from desalting unit, spent caustic solution, LPG sweetening unit, Service water used for washing, RO plant, crude tanks water draining and boiler blow down. Waste water typically contains oil and grease, dissolved materials, suspended solids, phenols, ammonia, sulphides, COD, BOD and other undesirable compounds.

All effluent water first taken in API separator where oil and grease contents captured and transferred to storage tanks. Effluent water then passes through holding basin where maximum oil and grease contents are captured. From holding basin effluent goes into treatment plant.

2.Dairy Farms

Milking Unit

The milking unit intake capacity is designed to handle 500 cows per day. Modern dairy farms have evolved from manual to automated milking systems. The milk extracted from each cow is transferred through a pipeline system into a bulk storage tank where it is rapidly cooled to maintain quality. The milk is stored in bulk tanks before being transported for further processing.

Milk Storage and Processing

Dairy farms are equipped with milk storage tanks that are cooled to a specific temperature to prevent spoilage. After collection, milk undergoes primary processing steps, including pasteurization to kill bacteria, homogenization for consistency, and sometimes further processing into products like butter, cheese, and yogurt.

Feed and Nutrition Management

Proper nutrition is critical to ensuring milk yield and quality. The feed management unit has an intake capacity of 1,000 kg of feed per day. It is designed to provide cows with a balanced diet rich in essential nutrients. Feed includes silage, hay, grains, and supplements, depending on the stage of lactation.

Waste Management System

The waste management system has a capacity of 10 m³ per hour and includes solid-liquid separation units to manage manure produced by the cows. The waste is processed to produce biogas, which can be used as an energy source on the farm, and the remaining solids are used as organic fertilizers. The waste management system also reduces odor and pollution, ensuring a clean environment.

3.Poultry Farms

Broiler and Layer Units

The broiler unit has a capacity of 10,000 chickens per batch, while the layer unit has a capacity of 5,000 hens producing eggs. Broilers are reared for meat, while layers are maintained for egg production. These units are equipped with automated feeders, waterers, and climate-controlled ventilation systems to ensure consistent growth rates and health.

Feed Management and Health Control

The feed unit processes approximately 2,000 kg per day of specialized feed, adjusted based on growth stages. Antibiotic-free diets and proper vaccination programs ensure healthy and quality birds. Feed is delivered via an automated system that minimizes waste and maximizes nutrition intake.

Egg Collection and Grading Unit

For the layer unit, eggs are automatically collected, graded, and packed for distribution. Grading is based on egg size and quality, ensuring that only premium eggs reach the market.

Waste Management System

The waste management system processes approximately 5 m³ of waste per day. Manure is collected and processed into fertilizer or compost, reducing environmental impact and generating additional income.

4.Stud Farm

Breeding and Training Facilities

The stud farm has facilities to house 100 horses and includes dedicated breeding and training areas. Breeding areas are designed to safely house both mares and stallions, while training areas include tracks and arenas for exercise and conditioning.

Feed and Health Management

The feed unit has a capacity of 500 kg per day, providing horses with high-quality grains, hay, and supplements. Regular veterinary care and a balanced diet ensure the horses are in optimal health, especially during breeding seasons.

Horse Care and Waste Management

Proper hygiene and waste management are maintained to prevent disease. A waste management system processes 3 m³ per day, converting waste into compost that is used for pasture maintenance.

5.Agriculture

Crop Production and Storage

The agricultural unit cultivates a range of crops, with a storage capacity of 5,000 metric tons. Grains, vegetables, and fruits are harvested and stored in silos, barns, or cold storage facilities, depending on the crop type.

Irrigation and Pest Management

Efficient irrigation systems, such as drip irrigation, are used to optimize water usage. Integrated pest management practices minimize the use of chemicals, maintaining a balance between crop yield and environmental health.

Livestock Management

The livestock unit includes cattle, poultry, and goats, focusing on meat, milk, and egg production. Feed is carefully managed, and regular veterinary care ensures animal health.

Post-Harvest Processing and Packaging

After harvesting, crops undergo cleaning, grading, and packaging to maintain freshness and quality, ready for distribution to markets.

6.Rice Industry

Milling Unit

The milling unit has an intake capacity of 1,200 metric tons per day. It includes processes for de-husking, polishing, and grading rice to produce high-quality grains for market. Different grades of rice are produced to meet specific consumer preferences.

Drying and Storage

Rice grains are dried to a moisture content of 12-13% to prevent spoilage and then stored in silos with a capacity of 3,000 metric tons. Proper drying and storage ensure extended shelf life and quality preservation.

Quality Control and Packaging

A quality control lab monitors attributes like grain size, moisture, and purity. Packaged rice is then distributed in various sizes for retail, bulk, and export markets.

7.Textile Industry

Spinning and Weaving Units

The spinning unit processes raw fibers into yarn, with an intake capacity of 1,000 kg per day. Yarn is then woven into fabric in the weaving unit, which has a production capacity of 800 meters per day.

Dyeing and Finishing

The dyeing unit has a capacity of 500 meters per day, where fabrics are dyed and finished for durability and colorfastness. Environmentally friendly dyes and water treatment systems ensure minimal environmental impact.

Quality Control and Packaging

Textile quality is assessed based on texture, color, and strength. Finished products are packaged according to customer specifications for export or domestic markets.

8.Surgical Instruments Industry

Manufacturing Unit

With a capacity of 5000 pieces per day, the unit produces precision surgical instruments. Techniques like forging, machining, and polishing ensure each instrument meets medical standards.

Sterilization and Quality Control

All instruments undergo sterilization before packaging to ensure they meet sterile and contamination-free standards required in medical settings. Instruments are thoroughly tested for precision, sharpness, and durability.

Packaging and Distribution

Sterilized instruments are individually packaged in sterile packs, labeled, and then distributed to hospitals and medical facilities.

9.Leather Garments Industry

Tanning and Processing

The cutting unit handles 5000 sq. meters of leather per day, and the sewing unit produces garments like jackets, gloves, and bags. Skilled artisans work alongside automated machines to ensure quality.

Cutting and Sewing

The cutting unit handles 500 sq. meters of leather per day, and the sewing unit produces garments like jackets, gloves, and bags. Skilled artisans work alongside automated machines to ensure quality.

Cutting and Sewing

Finished garments are inspected for strength, texture, and appearance. Each piece is then carefully packaged for distribution to retailers.

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