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Template No. 5-0000-0001-T2 Rev. 2 / 28.11.2014 Copyrights EIL – All rights reserved

Document No. A975-RP-02-42-0001

Rev. No. 1 Page 1 of 69

Pre-Feasibility Report for Guru Gobind Singh Polymer

Addition Project

HPCL Mittal Energy Limited

(HMEL)

Pre-Feasibility Report for Guru Gobind Singh

Polymer Addition Project

Submitted by:

Engineers India Bhawan, 1, Bhikaiji Cama Place, New Delhi – 110066





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Pre-Feasibility

Report

For

Guru Gobind Singh Polymer Addition

Project

Prepared by

New Delhi

December 2016





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Table of Contents

Section Content Page No

1 EXECUTIVE SUMMARY 5

2 INTRODUCTION 15

3 SCOPE OF WORK 18

4 BASIS OF STUDY 20

5 MARKET STUDY 23

6 PROJECT LOCATION 25

7 PROJECT DESCRIPTION 27

8 ENVIRONMENTAL CONSIDERATIONS 58

9 PROJECT IMPLEMENTATION & SCHEDULE 60

Annexures: Annexure-I: Block Flow Diagram Annexure-II: Project Implementation Schedule

Tables Summary

1. Table 1.1: Feed & Product Prices

2. Table 1.2: Summary of Results

3. Table 1.3 : Utility System Capacities for Petrochemical Block

4. Table 1.4: Additional Storage for Petrochemical Block

5. Table 1.5 : Project Capex

6. Table 2.1: Existing Unit Capacities & Licensors

7. Table 2.2: Existing Euro IV Product Slate for Crude Mix (AH:Doba= 90:10 wt%)

8. Table 3.1: Feed and Product Prices

9. Table 7.1.1: PFCCU & DCU Off Gases Composition

10. Table 7.2.1: Material Balance of Base case, KTPA

11. Table 7.2.2: Unit Capacities in Base case

12. Table 7.3.1: Summary of Results

13. Table 7.5.1: Utility Systems

14. Table 7.6.1: Offsite Storage Tanks





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ABBREVIATIONS

ASU Air Seperation Unit

BOO Build Own Operate

BTX Benzene Toulene Xylene

CDU Crude Distillation Unit

CFBC Circulating Fluidized Bed combustion

DCU Delayed Coker Unit

DEG Di Ethylene Glycol

DHDT Diesel Hydrotreater

EIL Engineers India Ltd

EVA Ethylene Vinyl Acetate

FG-ATU Fuel Gas Amine treating UNit

GE General Electric

GGSR Guru Gobind Singh Refinery

GOI Govt. of India

HDPE High Density Polyethylene

HGU Hydrogen Generation Unit

HMEL HPCL-Mittal Energy Limited

LDPE Low Density Polyethylene

LLDPE Linear Low Density Polyethylene

LNG Liquified Natural Gas

KCOT KBR’s Catalytic Olefinic Technology

MEG Mono Ethylene Glycol

MMBTU Million Metric British Thermal Units

MMTPA Million Metric tonnes per annum

NHT Naptha Hydrotreater

FCC-PC Fluid Catalytic Cracking-Petrochemical

PPU Polypropylene Unit

ROG Refinery Off Gas

SEZ Special Economic Zone

SNG Substitute Natural Gas

TPD Tonns Per Day

VAM Vinyl Acetate Monomer

VDU Vacuum Distillation Unit





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CHAPTER-1 EXECUTIVE SUMMARY





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1.0 Executive Summary

1.1 Introduction

HPCL Mittal Energy Limited (HMEL) currently operates a 9.0 MMTPA Guru Gobind

Singh Refinery in Bhathinda-Punjab, supplying EURO-III and EURO-IV compliant fuels

in the Northern region. The refinery is equipped with a Petro FCC and Delayed Coker

Unit with an upstream VGO+HCGO Hydrotreater; the configuration is fairly robust

and capable of maximizing the production of lighter distillates.

Propylene is one of the intended major products from the refinery which is close

coupled to a Poly Propylene Unit. The configuration provides a huge flexibility to the

refinery and currently matches well, with the product requirements. As part of the

original refinery, a Captive Power Plant was envisaged based on fuels from the

refinery, wherein LCO is utilized as fuel for the Power Plant besides fuel gas.

GGSRL is now undertaking a Low Cost Expansion of the existing refinery from 9.0

MMTPA to 11.25 MMTPA, wherein it is debottlenecking the existing units to achieve

this capacity. Additionally, a CFBC based steam generation system is also being

conceptualised, wherein, with coal/ Petcoke as fuel, steam and power shall be

generated. This will displace expensive fuels being used for power generation currently

thereby enhancing returns from the refinery.

As diversification in the field of petrochemicals due to the profitability and value

addition being higher in producing polymer products, the expansion of the refinery

considers integrating the same with a Petrochemical Complex in order to expand their

product portfolio while maximising the margins. The proposed Petrochemical block is to

be located within existing refinery battery limits.

This report details the various options studied to achieve this objective and their

findings.

1.2 Basis & Objectives

1.2.1 Basis

The salient points of the basis adopted for the study is as follows:

Target capacity of the refinery: Existing refinery at 11.25 MMTPA integration

with Petrochemical complex

Crudes: The crude has been considered as 90% Arab Heavy and 10% Doba.

Crude Assay: Assay provided by HMEL has been considered for the study

On stream Factor: 8000 hrs/ annum

Fuels productions (MS & Diesel) conforming to BS-IV has been considered.

Feed and product prices: The following sets of prices as provided by HMEL

have been considered.





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Table 1.1: Feed & Product Prices

S. No. Feed/ Product Revised Prices ($/MT)

1. Arab Heavy 877

2. Doba 877

3. LNG 858

4. LPG 1118

5. MS BS-IV 1222

6. Diesel (BS-IV) 1181

7. SKO 1238

8. ATF 1240

9. Petcoke 173

10. Sulphur 173

11. Naphtha –Exports 982

12. Hexane 979

13. Polypropylene 1890

14. HDPE 2001

15. LLDPE 1971

16. MTO 852

17. BTX 1210

18. Butadiene 1297

19. Bitumen 790

20. MEG 1445

21. DEG 1445

1.2.2 Objectives

The major objectives of the study are:

Evaluate integration of the existing refinery complex to a world class

petrochemical

Maximise value added petrochemical products from the refinery

Naphtha export from the refinery shall be "ZERO"

1.3 Process Description

The decision towards addition of Petrochemicals to the Refineries is always a critical

decision. To start with, whether the Petrochemical produce is to have aromatic

orientation or an olefinic orientation, itself, needs to be decided early. However, given

the proposition where the central upgrader in the refinery, as integrated above, is a

Petrochemical FCC, the decision is fairly obvious that to start with, the Petrochemical

Complex ought to have a olefinic orientation, such that, in addition to other





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advantages, the gas integration from DCU + FCC-PC to the proposed

Petrochemical Complex could exist to enhance gaseous feed stock to the olefin

complex. This will additionally enable recovery of ethylene from off gases

generated from Petro FCC, in the Olefin Complex, which is currently finding way

into the fuel gas pool. This is straightway a huge economic advantage achieved

through significant value addition.

The other important and critical issue is to ensure that the proposed cracker in the

refinery, essentially remains, with maximized gaseous feed stock and liquid feed to

the cracker to be brought in only, if warranted. Remember that the olefin complexes

begin to add value only through economies of scale and typically, 1 to 1.2 MMTPA of

ethylene produce are considered as a minimum economic size of an Olefin Complex to

maximise returns.

Feed Stock to Cracker

The key feed stocks considered for the Cracker are as listed below:

Off-gases from DCU – This stream is extremely rich in Ethane & Olefins

Off-gases from Petro FCC – This is a cut rich in Ethylene and ethane with little

quantities of propane as well.

The Paraffinic LPG from the integrated Refinery to the extent possible

Full Range Naphtha and Light Kerosene streams

Ethylene Recovery from FCC/ DCU Off-gases

At present in the 9 MMTPA refinery, the Refinery off gases from all the units is

collectively treated in the installed FG-ATU. To maximise the production of ethylene

from the refinery, the following routing of off gases from DCU & FCCU is proposed:

FCCU & DCU off gases shall be required at 14-15 Kg/cm2g at unit B/L and shall

then be routed to FG-ATU, similar to existing refinery.

The Amine treated gases from FG-ATU shall then be routed to Refinery off-

Gas treatment unit at 12.5-13 kg/cm2g.

The Refinery Off gas treatment unit of 450 KTPA capacity shall be considered.

Post De-Methanizer, the bottom product from De-Methanizer shall be pumped

to cracker’s De-ethanizer. Refinery Off gas and Cracker shall have a

common fractionation section

Cracker Unit Description

The Shortlisted case considers integration of the existing refinery complex with a

cracker unit with Straight run Naphtha and paraffinic LPG as feed. The duel feed

cracker will produce polymer grade ethylene and polymer grade propylene, raw C4

mix, raw pyrolysis gasoline and Pyrolysis fuel oil. Associated units like PSA unit,

Pyrolysis Hydrogenation Unit, Benzene Extraction Unit will be included in the Cracker

Block.

The Gas/ Naphtha cracker plant basically consists of two sections:





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Furnace Section

Separation Section

Furnace Section:

The heart of a Cracker plant is the cracking furnace system design and each Licensor

of a Cracker unit have individually optimised the furnace design. The main objectives

in cracking furnace design are:

Increase in Ethylene selectivity

Increase in Thermal efficiency

Reduction in fuel gas burners

Separation Section:

The Cracker technology suppliers are concentrating on simplifying the separation

section scheme to reduce the energy consumption in the plant and to reduce the

capital investment. The separation train consists of quench, compression, recovery

and refrigeration systems.

The quench oil section controls the gasoline end point, fuel oil flash point and

maximises heat recovery while in quench water system, cracked gas, water and tar are

separated. The light and heavy products are separated and light products are

compressed. After compression, caustic scrubbing and drying, the light effluents enter

the cold section of the unit which performs the separation of

a) Hydrogen

b) Polymer grade ethylene

c) Polymer grade propylene

d) C4 mix stream

e) Pyrolysis gasoline which is rich in aromatic hydrocarbons.

The following products shall also be separated out in the downstream Associated Units

a) Benzene

b) Hydrogenated Pyrolysis Gasoline

c) C9+

d) CBFS

Proposed Downstream Polymer Units

The following is proposed for the Polymer Block:

1. All the ethylene produced in the Complex could be captively converted to value

added products.

2. Introduce a world scale size Swing Unit for producing LLDPE/HDPE

3. Introduce a standalone HDPE Unit in the complex for total consumption of

Ethylene produced and enhancement of Polymer variety.

4. The complex shall have its own Butene-1 facility commensurate to the

requirement in Polyethylene plants as co-monomer.

5. Introduce additional chains of Poly Propylene Unit to captively convert all the

propylene produced from the Petrochemical Complex.





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6. The Non aromatic Pyrolysis Gasoline product from the petrochemical complex to

be routed to refinery Gasoline pool.

7. It is proposed that all the BTX produced from the complex, benzene may be

recovered and rest Toluene + mixed xylene have been considered for sales only.

1.4 Unit Capacity & Product Slate

The product slate and capacities of major units in the petrochemical block are indicated

in the table below

Table 1.2: Summary of Results

Case Description Base Case Project case

Products, KTPA

LPG 807 593.3

Naphtha 237 0

HDPE/ LDPE 1195.3

Benzene 79

Mixed Xylenes 161

Hexane 5 5.0

Gasoline (BS-VI) 1533 993.3

Kerosene 200 100

ATF 303.3 400

MTO 25 25

Diesel (BS-VI) 4955 3946

Bitumen 500 500

Coke 598 565

Sulphur 209.5 213.5

Fuel and Loss 1461.2 1723.3

PP-Regular 466.7 791.3

PP-Impact - 150

Low Sulphur Fuel Oil - 15

Unit Capacities, KTPA

Cracker, KTPA ethylene - 1200

LLDPE/HDPE swing unit - 2 x 400

HDPE - 1 x 450

Polypropylene Unit - 1x 500

Butene-1 - 1 x 55

Offgas Treatment - 450

1.5 Block Flow Diagram

The block flow diagram for the refinery integrated with petrochemical process is

attached as Annexure-I.

1.6 Utility System Capacities

The following additional utility systems shall be required to cater to the petrochemical

block as well as for the polymer units considered.





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Table 1.3: Utility System Capacities for Petrochemical Block

Utility Selected Case

Steam -

Power to be purchased 220 MW

Power from STGs -

Cooling water, M3/hr

(34+3) Nos. cell of 4000m3/hr each + (17 +5) pumps

of 8000m3/hr each. 8 Future cells have also been

envisaged for future requirement.

Inst Air & Plant Air

Compressed Air System to be designed for 27000

Nm3/hr. For instrument air 3 dual bed adsorption

based dryers of capacity 4000 Nm3/hr each are

provided. Also 1 nos. 500 Nm3/hr of back up HP air

reciprocating compressor

Nitrogen

2 chains of 8600 Nm3/hr of gaseous N2 and liquid

equivalent to be optimized. Vaporizer capacity of

12000 Nm3/hr (steam bath).

Nitrogen tanks 2 X 1900 m3 liq N2 atm storage.

1X6 m3 pressurized double walled storage vessel.

Notes:

1. Deleted.

2. Power import for the expansion facility shall be sourced from the grid. This has

been accounted in OPEX.

3. It is considered that the existing steam utility boilers shall be used for additional

steam requirement.

4. New ETP for petchem block

5. Total normal raw water requirement for the expansion facility comes to around

3500 m3/hr. Raw water storage for 14 days has been considered.

6. The Petrochem block shall have following Flare systems:

Main Hydrocarbon Flare for Cracker and Auxiliary utility

Sour flare system for Caustic oxidation facility of Cracker + Auxiliary unit

Cryogenic flare for Ethylene storage

Polymer Flare system for all polymer units

2.1 Offsite Storage

Off-site storages have been considered for all the feed, intermediate and solids product

storage and dispatch for the Petrochemical block.

Table 1.4: Additional Storage for Petrochemical Block

Facility Storage Capacity m3

( Each pumpable)

Nos. of Tanks/ vessels

Days of storage

Type Remarks

Ethylene 24000 2 7 days DWST Each tank to have submersible





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pump of 150 M3/hr( 2+1). Vaporizer & BOG system also to be

considered as for all ethylene Tanks

Off- spec Ethylene

1500 1 5 hours Sphere 1+1 pump of 133 M3/hr

Propylene 13000 2 8 days DWST Each tank to have submersible pump of 65M3/hr ( 2+1). Vaporizer

& BOG system also to be considered.

Off-spec Propylene

1870 1 12 hours Mounded Bullet

1+1 pump of 15 M3/hr Centrifugal pump each

C4 mix 2380 4 3 days Sphere 2+1 pump of 65 M3/hr Centrifugal pump each

Off-spec C4 mix

2380 1 1 day Sphere 1+1 pump of 15 M3/hr Centrifugal pump each

RPG 10,000 2 7 days Dome roof + N2

blanketing

Feed to PGH unit. (1+1)X 65 m3/hr Centrifugal pump each

C6 Cut 2200 3 6 days IFR + N2 blanketing

Feed to BZ extraction unit. C6 raffinate shall also be routed here only. (1+1) X 50 m3/hr centrifugal

pump each.

Product Tanks

Benzene 3700 3 16 IFR + N2 blanketing

Final Product for dispatch

PFO/ CFBS 2500 2 15 Cone Roof + N2

blanketing

Shall be routed to refinery FO or dispatched as CBFS

Hydrogenated

Pyrolysis Gasoline

9000 2 27 IFR + N2 blanketing

to be routed to Refinery Gasoline Pool

C9+ Cut 1400 2 14 Cone Roof + N2

blanketing

shall be routed to refinery

C6+ oligomer

300 2 28 IFR + N2 blanketing

Shall be dispatched as final product.

Hexene-1 2500 1 - Cone Roof + N2

blanketing

Shall be utilized in LLDPE/HDPE swing unit

Hexane 500 1 - IFR + N2 blanketing

Shall be utilized in HDPE unit

Pentane 250 1 - Bullet with Nitrogen

Blanketing


Slop 500 1 IFR + N2 blanketing

Crude Oil 60,000 1 Floating Roof

2.2 CAPEX and IRR





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The cost has been worked out based on broad system capacities estimated for the

shortlisted case. The cost indicated in the table is based on the following:

Cost estimate is as on 2nd quarter of 2016.

Cost estimate accuracy is ± 30%

The project execution is based on conventional mode.

The following major cost factors among other factors are excluded from CAPEX

estimation:

Land cost

Piling

Pipeline costs or additional Railway Sidings

The various parameters considered for estimating IRR is as follows:

1 Construction Period 48 months

2 Period of Analysis 15 years

3 Debt / Equity Ratio 2:1

4 Expenditure Pattern Equity before Debt

5 Loan Repayment period 8 years

6 Moratorium Period 2 Year

7 Interest on LT Loan 11.0%

Interest ST Loan 12.0%

8 Capital Phasing (Total Capital)

1 Year 15%

2 Year 25.0%

3 Year 35.0%

4 Year – Spill over after const. period 25.0%

9 Capacity Build – up

1st year 90%

2nd year onwards 100

10 Corporate Tax Rate @ 30%+ 12% surcharge+ 3% Education cess = 34.61%

11 MAT @ 18.5%+ 12% surcharge+ 3% Education cess = 21.346%

12 CENVAT Benefit Not considered

The project financials arrived at based on factors listed above is tabulated in

table 1.5.

Table 1.5: Project Capex

S. No Description Project Financials

1 CAPEX 19635*

2 OPEX Excl Feed Cost Feed Cost

2104.13 894.88

3 Margin (Sales-Opex) 5355.52





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* The CENVAT component for the selected case is Rs. 1550 Crores.

2.3 Site and Layout

The proposed Project shall be located in the existing Refinery Complex in Bhatinda, Punjab. The overall land required for the project is 170 hectares (plant area excluding green belt). There is sufficient land in existing refinery to cater to this additional requirement for Petrochemical complex.

2.4 Environmental Considerations

For environmental considerations, adequate care will be taken during

conceptualization of the project and in process design to minimize the quantity of

waste produced. In addition, solid, liquid and gaseous wastes generated from various

processes in the complex will be handled in a manner that minimizes their impact on

the environment.

Some of the measures to be taken are as follows:

Solid Waste - It is recommended to dispose off solid waste such as spent catalyst,

tank bottom sludge and ETP sludge in secured landfills outside the complex.

Liquid waste - A fully fledged Effluent Treatment Plant (ETP) has been considered

for the petrochemical complex to treat various liquid effluents generated in the

refinery complex.

Gaseous Effluents - Atmospheric emissions related to the proposed facilities

emanate mainly from the stacks located in various process units and in the CPP.

- SOx Control – The overall SOx emissions from the complex shall be restricted

to the present permissible value of 23.8 TPD.

- NOx Control - Low NOx burners shall be recommended to reduce NOx

emission from all furnaces.

1.11. Conclusion

Based on the above analysis, the following is concluded:

1. The Project is extremely viable with a very high return of 17.23% post tax, based

on the product prices, as mentioned, elsewhere in the Report.

2. The petrochemical complex in the current scenario, enhanced profitability linked

with Petrochemical produce is an extremely desirable option for the Refinery

as apart from other things it provides a huge flexibility to HMEL to switch

between distillates and petrochemical produce.

4 IRR (Post Tax) 17.23%





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3. The petrochemical complex will lay the foot prints for further expansion of the

refinery/petrochemical complex for exploitation of niche derivatives flexibility

and control towards diesel produce.

4. Further optimization on the aromatics and above all further make the HMEL

complex a world scale size in the times to come.





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CHAPTER-2 INTRODUCTION





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2.0 INTRODUCTION

The Guru Gobind Singh Refinery set up by HPCL-Mittal Energy Limited (HMEL) has

been designed to process 9.0 MMTPA of high sulphur crudes (100% AM and 90:10

AH:Doba).

The processing facilities at the refinery primarily consist of the following units:

Table 2.1: Existing Unit Capacities & Licensors

UNIT Design Capacity

(MMTPA) Licensor

CDU/VDU 9.0 EIL

NHT/ NSU 0.94 Axens

CCR 0.5 Axens

ISOM 0.32 Axens

DHDT 4.1 Axens

FCC-PC 2.2 Shaw

VGO HDT 3.0 Axens

DELAYED COKER 2.76 CBI Lummus

POLYPROPYLENE 440 KTPA Novolene / CBI Lummus

HGU 2X44 KTPA HTAS

SRU 2 X300 TPD Prosernat

SWS-I & II 294 T/hr & 104 T/hr EIL

ARU 674 T/hr (Rich Amine) EIL

LPG TREATER

12 T/hr (CR LPG), 30 T/hr (SR LPG)

EIL

ATF TREATER 0.55 UOP

Apart from these process units, refinery also has commensurate Utilities & Offsite

facility including Captive Power plant.

The refinery is capable of producing 100% EURO-IV fuels products. The product slate for AH+Doba crude case is provided in Table below





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Table 2.2: Existing Euro IV Product Slate for Crude Mix (AH:Doba= 90:10 wt%)

S.N. Description Quantity (Design) (Euro-IV), KTPA

1 LPG 800

2 Naphtha + Hexane 437 + 20

3 Gasoline (including Premium) 1050

4 Poly Propylene 414

5 Kerosene + ATF 702

6 Diesel + MTO 3704

7 Pet Coke 859

8 Sulphur 175

Since the refinery is already equipped with a Petro FCC and Delayed Coker Unit with

an upstream VGO+HCGO Hydrotreater, the configuration is fairly robust and

capable of maximizing the production of lighter distillates. Propylene is one of the

intended major products from the refinery which is close coupled to Poly Propylene

Unit. The configuration provides a huge flexibility to the refinery and currently matches

well, with the product requirements. As part of the original refinery, a Captive Power

Plant was envisaged based on fuels from the refinery, wherein LCO is utilized as fuel

for the Power Plant besides fuel gas. In the interim GGSRL has already launched a

CFBC based steam generation system, wherein, with coal as fuel, steam and power

shall be generated to displace, the expensive fuels being used for power

generation currently. This will enhance returns from the refinery even further.

HMEL now intends to expand its product portfolio to include petrochemical products

(LLDPE/HDPE and Poly-Propylene) as well as explore their derivatives by utilizing the

excess naphtha/LPG produced from the refinery.

With the above background, HMEL have approached EIL to carry out a preliminary

study to address the above objective.





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CHAPTER 3 SCOPE OF WORK





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3.0 SCOPE OF WORK

3.1 The scope of work of the study report is detailed in this section. The following activities

shall be performed.

1. Carry out configuration study for the integration of the refinery complex with an

olefin complex. Identify the best suited configuration based on economics as well

as reliability.

2. Develop the Final Product Pattern

3. Estimate utility requirement for the expanded capacity & offsite storage facilities

(feed, intermediate product as well as finished product)

4. The capacity of the new utility generation system will be worked out based on the

design capacity of the existing facilities. Additional Utility and Offsite facilities

required shall be identified and quantified.

5. No integration with existing utility system

6. Develop preliminary cost estimate for each of the options:

i. For process units, capital cost shall be based on unit level costs.

ii. For utilities and offsites/ infrastructure, capital cost shall be based on the

facilities identified for each of the options.

7. Economic analysis based on GRM/simple payback

8. Recommendation of selected configuration.

9. Preparation of Study Report.

3.2 Deliverables

The deliverable of the study is the Pre-Feasibility report.

3.3 Exclusions

The following items are specifically excluded from the scope of current feasibility study

Market Study

Health checking and condition assessment of the existing hardware





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CHAPTER-4 BASIS OF STUDY





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4.0 BASIS OF STUDY

4.1 Refinery Capacity : Existing refinery @11.25 MMTPA integration with

petrochemical complex.

4.2 Design Crude Mix : 90:10=AH: Doba

4.3 Crude Assay : Refer Annexure-1

4.4 Fuels Specifications : Refer Annexure-2

4.5 Objectives of the Study

Evaluate a world-class grass-root petrochemical complex, integrated to refinery.

Maximise value added petrochemical products from the complex

Naphtha export from the refinery shall be "ZERO"

Evaluate options for ethylene and propylene derivative production

4.6 Feed and Product Prices

Feed and product prices have been considered as provided by HMEL.

Table 4.1: Feed and Product Prices

S. No. Feed/ Product Prices ($/MT)

1. Arab Heavy 877

2. Doba 877

3. LNG 858

4. LPG 1118

5. MS BS-IV 1222

6. Diesel (BS-IV) 1181

7. SKO 1238

8. ATF 1240

9. Petcoke 173

10. Sulphur 173

11. Naphtha –Exports 982

12. Hexane 979

13. Polypropylene 1890

14. HDPE 2001

15. LLDPE 1971

16. MTO 852

17. BTX 1210





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18. Butadiene 1297

19. Bitumen 790

20. MEG 1445

21. DEG 1445

4.7 Data Used for Study

The yield data for the existing units is based on the actual operating capacities and

yields of individual units provided by HMEL. The yield data for new units is based on

EIL in-house databank.

4.8 Availability of Natural Gas

Natural gas shall be considered as available for use as Feed and fuel for the new

HGU. The naphtha displaced in the process shall be diverted for production of olefins.





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CHAPTER 5.0 MARKET STUDY





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5.0 MARKET STUDY

Market study is not included in the present scope of work. The product demand as

given by HMEL is considered.





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CHAPTER 6.0 PROJECT LOCATION





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6.0 PROJECT LOCATION

The proposed project is in the existing refinery located in Bhatinda, Punjab. The overall area required for the project is 170 hectares (plant area excluding green belt). There is sufficient land in existing refinery to cater to this additional requirement for Petrochemical complex.





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CHAPTER 7.0 PROJECT DESCRIPTION





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7.1 Methodology Adopted for the study

The methodology adopted for the study is as below:

LP model was tuned with the current operating and production data provided by HMEL

Base case for the refinery for a throughput of 11.25 MMTPA has been established.

Configuration study has been carried out with integrating a petrochemical complex.

No revamp or modification in the existing facilities has been considered.

Utility systems and offsite systems have been worked out for the various options.

Cost estimates for all the facilities shall be estimated based on above inputs.

Financial analysis for the project shall be estimated.

7.1.1 Cracker Unit & its Feedstock

The decision towards addition of Petrochemicals to the Refineries is always a critical

decision. To start with, whether the Petrochemical produce is to have aromatic

orientation or an olefinic orientation, itself, needs to be decided early. However, given

the proposition where the central upgrader in the refinery, as integrated above, is a

Petrochemical FCC, the decision is fairly obvious that to start with, the Petrochemical

Complex ought to have a olefinic orientation, such that, in addition to other

advantages, the gas integration from DCU + FCC-PC to the proposed

Petrochemical Complex could exist to enhance gaseous feed stock to the olefin

complex. This will additionally enable recovery of ethylene from off gases

generated from Petro FCC and DCU in the Olefin Complex, which is currently

finding way into the fuel gas pool. This is straightway a huge economic

advantage achieved through significant value addition.

Feed Stocks to Cracker

The key feed stocks considered for the Cracker are as listed below:

Off-gases from DCU – This stream is extremely rich in Ethane & Olefins (refer

table 7.1.1).

Off-gases from Petro FCC – This is a cut rich in Ethylene and ethane with little

quantities of propane as well.

LPG from the integrated Refinery to the extent possible

SR Naphtha and Kerosene streams (up to end point of 250°C) as is necessary

to meet a cracker capacity of 1200 KTPA ethylene.





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Table 7.1.1: PFCCU & DCU Off Gases Composition

Parameter Design Specification

Specification Range

Test Method

Composition, Vol%

Methane 42.88 UOP 539 Ethane 14.23 UOP 539

Ethylene 23.08 UOP 539 Hydrogen 9.69 UOP 539 Hydrogen Sulfide 0.01 UOP 539 Iso Butane 0.11 UOP 539 Iso Pentane 0.11 UOP 539 N Butane 0.21 UOP 539

Nitrogen 6.01 UOP 539

n-Pentane 0.11 UOP 539

Oxygen 0.42 UOP 539

Propane 0.42 UOP 539

Propylene 0.63 UOP 539

C4 Unsaturated 0.42 UOP 539

C5 Unsaturated

C6+ heaviers 0.11

0 UOP 539

UOP 539 Carbon Dioxide 0.95 UOP 539

Carbon Monoxide 0.63 UOP 539

Impurities

Components Unit Design Specification (Max) Methanol, wt-ppm ppmw 0.2

Aldehydes, wt-ppm ppmw 0.4

1-Methanethiol, wt-ppm ppmw 12

Dimethylsulphide, wt-ppm ppmw 1

COS, wt-ppm ppmw 5

Hydrogen Cyanide, wt-ppm ppmw 0.5

Acetonitrile, wt-ppm ppmw 0.5

Amines, wt-ppm ppmw 0.1

Phosphine, wt-ppm ppmw 0.5

Arsine, wt-ppb ppb w 0.1

NOx, vol-ppm ppmv 60

Al, wt-ppm ppmw 0.8

Ca, wt-ppm ppmw 10

Fe, wt-ppm ppmw 0.2

K, wt-ppm ppmw 4

Mg, wt-ppm ppmw 0.3

P, wt-ppm ppmw 0.5

Si, wt-ppm ppmw 0.3

Sn, wt-ppm ppmw 0.2

Other metals, wt-ppm ppmw 0.1





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7.1.2 General Description of Gas/ Naphtha Cracker

The Gas/ Naphtha cracker plant basically consists of two sections:

Furnace Section

Separation Section

Furnace Section:

The heart of a Cracker plant is the cracking furnace system design and each Licensor

of a Cracker unit have individually optimised the furnace design. The main objectives

in cracking furnace design are:

Increase in Ethylene selectivity

Increase in Thermal efficiency

Reduction in fuel gas burners

Separation Section:

The Cracker technology suppliers are concentrating on simplifying the separation

section scheme to reduce the energy consumption in the plant and to reduce the

capital investment. The separation train consists of quench, compression, recovery

and refrigeration systems.

The quench oil section controls the gasoline end point, fuel oil flash point and

maximises heat recovery while in quench water system, cracked gas, water and tar are

separated. The light and heavy products are separated and light products are

compressed. After compression, caustic scrubbing and drying, the light effluents enter

the cold section of the unit which performs the separation of

e) hydrogen

f) Polymer grade ethylene

g) Polymer grade propylene

h) C4 mix stream

i) Pyrolysis gasoline which is rich in aromatic hydrocarbons.

7.1.3 Refinery Off Gases Routing & Integration with Cracker

At present in the 9.0 MMTPA refinery, the Refinery off gases from all the units is

collectively treated in the installed FG-ATU. To maximise the production of ethylene

from the refinery, the following routing of off gases from DCU & FCCU is proposed:

FCCU & DCU off gases shall be routed to FG-ATU, similar to existing refinery.





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The Amine treated gases from FG-ATU shall then be routed to Refinery off-gas treatment unit.

The Refinery Off gas treatment unit shall be of 450 KTPA capacity & shall consist of following:

Refinery off gas ( ROG)-Caustic/ water wash tower along with pumps

ROG Dryer & ROG dryer KOD

Refinery dry gas(RDG) oxygen convertor effluent cooler, RDG oxygen

convertor Feed heater & RDG oxygen convertor

RDG Dryer & RDG dryer effluent filter

RDG Cold box Exchanger (the chilling stream of cold box are integrated

with cracker streams)

RDG De-Methanizer, RDG de-methanizer Reboiler, RDG de-methanizer

Condenser, RDG De-methaniser pumps & RDG De-methaniser reflux

drum.

RDG De-ethanizer, RDG De-ethanizer reboiler, RDG de-Ethanizer

Condenser & RDG De-Ethaniser Reflux drum

Post De-Methanizer, the bottom product from De-Methanizer shall be pumped

to cracker’s De-ethanizer. Refinery Off gas/ KCOT and Cracker shall have

a common fractionation section

The recycle C2’s & C3’s shall be routed to Cracker furnace only along with

other recycles.

Please note that a separate off gas treatment, de-methaniser & De-ethaniser

section is required due to massive gas volume of off gases. Post De-

ethaniser, it can be integrated with cracker’s fractionators.

7.1.4 Overall Feedstock for the Integrated Petchem Complex

Thus, the overall feedstock for Integrated Petrochemical complex shall be:

SR Naphtha and Light Kerosene to Naphtha Cracker

Offgases from DCU + PFCCU

LPG to Gas Cracker Furnace

7.1.5 Proposed Downstream Polymer Units

From the above, it may be observed that significant Ethylene and Propylene is

produced from the Integrated Complex which can be utilized for putting together a

downstream Polymer based Petrochemical Block. The following is proposed:

1. All the ethylene produced in the Complex could be captively converted to value

added products.

2. Introduce a world scale size Swing Unit for producing LLDPE/HDPE

3. Introduce a standalone HDPE Unit in the complex for total consumption of

Ethylene produced and enhancement of Polymer variety.

4. The complex shall have its own Butene-1 facility commensurate to the requirement

in Polyethylene plants as co-monomer.





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5. Introduce additional chains of Poly Propylene Unit to captively convert all the

propylene produced from the Petrochemical Complex.

6. The Non aromatic Pyrolysis Gasoline product from the petrochemical complex to

be routed to refinery Gasoline pool.

7. It is proposed that all the BTX produced from the complex, benzene may be

recovered and rest Toluene + mixed xylene have been considered for sales only.





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Section 7.2 Base Case





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7.2 Base Case

The refinery is currently undergoing a low cost expansion to increase the refinery

throughput from 9.0 MMTPA to11.25 MMTPA with following modifications:

Petcoke based CFBC boiler

New Bitumen Blowing Unit of 500 KTPA capacity

3rd reactor in existing Polypropylene Unit to cater to additional polypropylene

production

While the model has been validated for a base case of 11.25 MMTPA with BS-VI

production for economic analysis.

7.2.1 Material Balance

The material balance of base case with BS-VI production is provided in Table 7.2.1

below:

Table 7.2.1: Material Balance of Base case, KTPA

FEED 11.25 MMTPA

Doba 1125

Arab heavy 10125

PRODUCTS

LPG 807

Naphtha export 237

Hexane 5

MS VI Regular 1533

Kerosene 200

ATF 303.3

MTO 25

HSD VI 4955

Polypropylene 466.7

Bitumen 500

Sulphur 209.5

Coke 598

Fuel & Loss 1421.2

7.2.2 Capacity Utilization of Existing Process Units

The Capacity utilization of existing process units is provided in Table 7.2.2 below:





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Table 7.2.2: Units Capacities in Base case

Unit Design capacity

(KTPA)

Base case-11.25 MMTPA (KTPA)

CDU/VDU 9000 11300

NHT 940 1225

CCR 500 550

ISOM 320 369

DHDT/ New DHT 4140 4340/ 1900

VGOHDT 3000 3219

FCC-PC 2220 2956

DCU 2700 3153

BBU 500 500

HGU 88 102

PPU 440 467





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Section 7.3 Analysis of Configuration Options





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7.3 Analysis of Configuration Options

7.3.1 Options Studied

Based on the objectives set in the basis and keeping the proposed scheme in mind,

various options under11.25 MMTPA refinery with cracker were worked out to provide

the suitable value add for the complex configuration. The brief description of the same

is as follows:

11.25 MMTPA + Cracker

Straight Run naphtha, Light kerosene and LPG routed to Cracker.

FCCU & DCU Off gases to Off Gas treatment unit and then recovery of

Ethylene.

All C2/C3 recycle from common fractionator section (including FCCU/

DCU Offgases) are routed to cracking furnace

Balance Naphtha streams being routed to MS pool and No naphtha

Sales. MS sales limited to a maximum of 1.0 MMTPA

1. For the above scenario, LPG has been limited to a maximum of 600 KTPA and

MS production has been limited to a maximum of the current production level of

1.0 MMTPA.

The following products were analysed for the downstream polymer block:

Production of LLDPE or HDPE: These are fairly robust units and installed in

various locations in India. There are number of Licensors offering this

technology and has substantial demand potential in the market.

Production of MEG (DEG & TEG as by product) : Even though MEG adds

value to the product profile, the production of MEG has not been considered as

this unit will increase the cost of the plant by roughly 2000 Crores and marginal

increase in the IRR. It is highly price sensitive.

Production of LDPE/EVA: LDPE/EVA is a prospective niche petrochemical

polymer and is gradually gaining significance/ demand. However, the

technology for the moment is restricted between 3 licensors and apparently

indicates a significant proprietary content both in terms of design and

equipment. Typically the units are of extremely high pressure ranging between

2500 to 3000 bar. This is an extremely high capex unit.

In view of the above it has been considered that only conventional polymers i.e. LLDPE

and HDPE be considered as of now. Other products may be considered as a future

option. The results considering production of LLDPE and HDPE are tabulated below.

7.3.2 Unit Capacity and Product Slate

The unit capacity and product slate for the selected case is tabulated in table 7.3.1

below.

Table 7.3.1: Summary of Results

Case No. C1E

Feed, KTPA With kerosene Cracking

Crude 11,300





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Natural Gas 155.7

Naphtha Import -

Products, KTPA

LPG 593.3

Naphtha 0.0

Gasoline 993.3

Kero 100

ATF 400

Diesel 3946

Hexane 5.0

MTO 25.0

Sulphur 213.5

Coke 565

Bitumen 500

LLDPE / HDPE 1195

PP – Regular 791.3

PP - Impact 150

Benzene 79.0

Mixed Xylenes 161

Low Sulphur Fuel Oil 15

Fuel & loss 1723.3

Unit Capacities, KTPA

Cracker 1200

LLDPE/HDPE Swing 2X400

HDPE 1X450

MEG -

PP 1X500

Butene-1 1X55

7.3.3 Block Flow Diagram

The block flow diagram for the refinery integrated with petrochemical complex is

attached as Annexure-I.





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Chapter 7.4 Process Description





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7.4 Process Description

7.4.1 Steam Cracker Unit

Feed, Cracking, Quench

Ethane rich feed is preheated against waste process heat and introduced into the cracking furnaces. The C3+ stream is vaporized and superheated prior to being introduced into the cracking furnaces. The naphtha/ kerosene feed is preheated against waste process heat and introduced into the cracking furnaces. Recycle ethane is mixed with the ethane rich fresh feed for cracking in the furnaces. Recycle C3 stream containing propane only is in a gaseous state and it is mixed with the C3+ fresh feed for superheating. The primary process step in producing olefins from hydrocarbon feeds is thermal cracking, usually referred to as pyrolysis. This process converts the feed to lower molecular weight hydrocarbons at relatively high temperature and low pressure. The cracking reactions take place in furnace coils to which dilution steam is added. Steam reduces the hydrocarbon partial pressure to promote the production of olefins and minimize the rate of coke deposition. Furnace coil operating conditions of temperature, residence time and hydrocarbon partial pressure will be selected to optimize olefin yields during the detailed design phase. Periodic decoking is required to remove coke which accumulates gradually in the radiant coils and quench exchangers. The furnaces will be steam/air decoked when the tube metal temperature approaches its design limit. After several steam/air decoke cycles, fouling in the SLEs will require a cold shutdown to hydro blast the exchangers. Effluent gas from the furnaces is rapidly quenched in quench exchangers by generating steam. Rapid cooling is necessary to avoid secondary reactions, which convert valuable products to heavier materials that tend to cause fouling in the exchangers. The steam generation pressure is set so that the tube wall temperature is high enough to prevent condensation of hydrocarbon in the SLEs. Steam generated in the quench exchangers is superheated in the cracking furnace convection sections and used in the turbine driver for the cracked gas compressor.

Furnace effluent gas is cooled further by direct contact with circulating quench oil and fractionated in a quench oil tower to remove the heavy fraction. This quench oil slip stream is stripped to control flash point and sent to storage as fuel oil product. Heat removed from the cracked gas by the quench oil is used to preheat naphtha feed, superheat gas feed, heat water stripper feed, and reboil the distillate stripper. Overhead from the quench oil tower enters the quench water tower. Most of the dilution steam condenses in this tower, along with a portion of the gasoline fraction. Cooling is achieved by a circulating quench water system which is used as heating medium for deethanizer reboiler and additionally the propylene tower reboiler. Quench water is separated from hydrocarbon in the main compartment of the water quench tower and recycled through the exchangers and water coolers back to the tower. Hydrocarbon liquid is returned to quench oil tower as reflux.

The net process water condensate is pumped through a filter and coalescer to remove solids and free oil, and is then preheated, stripped and delivered to the dilution steam generator, where steam is generated by exchange with MP steam. Blow down from the dilution steam drum is cooled and delivered to battery limits for further treatment. With





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this system, dilution steam is generated in a closed loop, thereby reducing the quantity of feed water makeup and oily waste water from the plant.

Compression, Caustic Washing and Drying

Cracked gas from the quench water tower is first compressed in four stages of the cracked gas compressor. Hydrocarbon condensate from the first four stages is fed to the distillate stripper which also receives hydrocarbon from the water quench tower. The stripped gasoline is pumped to OSBL. Acid gases (H2S and CO2) produced in the cracking furnaces are removed from the cracked gas in a caustic wash tower. This column contains two caustic circulating sections followed by a water wash section to prevent caustic entrainment. Makeup caustic is diluted before injection. Spent caustic is deoiled using gasoline, degassed and pumped to the battery limits for treatment. Removal of acid gas at this point in the process allows all of the C4 and lighter hydrocarbons to be desulfurized together, eliminating the necessity to clean individual product streams.

Overhead gas from the caustic tower is cooled with propylene refrigerant, and the uncondensed portion goes forward to cracked gas dehydrators. The condensate is pumped forward to the HP depropanizer via the liquid dryer unit. Essentially, complete removal of water is necessary to prevent freeze-ups in subsequent low temperature equipment.

Depropanizers and Acetylene Removal

The dried gases are cooled and fed to the HP depropanizer, which separates the feed into an overhead vapor essentially free of C4 and heavier material and a bottoms product essentially free of C2 and lighter material. Tower overhead vapor is compressed in the fifth stage of the cracked gas compressor. Net bottom flows to the LP depropanizer. The LP depropanizer produces a raw C3 liquid distillate (containing propylene and propane) which is sent to C3 hydrogenation. The LP depropanizer produces a bottoms C4+ stream which is fed to the depentanizer. Gas from the fifth stage of the cracked gas compressor is catalytically hydrogenated to remove acetylene. The reactor feed gas may either be cooled or heated, depending on the age and activity of the catalyst. Catalyst life is expected to be at least three years between regenerations. Three catalyst beds are used, with intercooling between beds to limit the temperature rise per bed. Essentially, all acetylene is converted to ethylene and ethane. Some of the methyl acetylene and propadiene is converted to propylene. Effluent from the reactor is cooled and dried in a secondary dryer to remove any trace quantities of water. Dried gas is cooled and partially condensed to provide reflux for the HP depropanizer. Net HP depropanizer overhead vapor goes forward to the demethanizer prefractionator feed chillers while net overhead liquid flows directly to the demethanizer prefractionator.





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Cold Fractionation - Demethanizer System

HP depropanizer overhead vapor product is chilled by exchange with ethane recycle and successively colder levels of propylene and ethylene refrigeration. Liquids separated in the chilling train are fed to appropriate trays in the demethanizer prefractionator and demethanizer, according to composition. The demethanizer prefractionator receives three feeds: liquid from the HP depropanizer reflux drum, liquid fractionated from the cracked gas in the demethanizer prefractionator feed drum and liquid condensed from the cracked gas in dephlegmator number 1. The prefractionator separates C3 and heavier material from C2 and lighter. The overhead vapor from the prefractionator, which contains essentially no C3 material, is sent to the demethanizer via the demethanizer feed rectifier. The prefractionator bottom is sent to the deethanizer.

The demethanizer makes a sharp separation between methane and ethylene. The tail gas streams are warmed in a series of core exchangers by exchange with demethanizer feed and propylene refrigerant liquid. Demethanizer reboiler heat is supplied by condensing propylene refrigerant vapor. The demethanizers, dephlegmators and core exchangers achieve the low temperature separation required at minimum energy cost and with very small loss of ethylene to tail gas streams. The final cooling produces a crude hydrogen stream, which is reheated in the cold box exchangers and delivered to the PSA Unit. Cold Fractionation - Deethanizer and C2 Splitter Systems The deethanizer separates the demethanizer prefractionator bottoms into C2’s and C3’s. The net overhead, consisting principally of ethylene and ethane, is taken as a liquid to a C2 splitter, while the net bottom is fed to C3 hydrogenation. The reboiler is heated by quench water and the condenser heat is removed by propylene refrigerant. The C2 splitter is a single tower operated at low pressure and temperature. Two feeds enter the tower; an ethylene rich vapor stream from the demethanizer and the overhead liquid product from the deethanizer. The C2 splitter operates with the C2 refrigeration compressor as a heat pump system. The overhead vapor from the tower is compressed, entering the third stage of the compressor. There are intermediate and bottom reboilers, heated by condensing ethylene refrigerant from the third and fourth stages of the ethylene refrigeration compressor, respectively.

The C2 splitter makes a sharp separation between ethylene and ethane. The ethylene product is pumped to high pressure, heated, and delivered to battery limit as a vapor product. Ethane bottom from the splitter is pumped and vaporized by exchange with demethanizer feed, and recycled to the cracking furnaces. Hot Fractionation - C3 Hydrogenation and C3 Splitter and Depentanizer Systems

Raw C3’s from the deethanizer bottom and LP depropanizer overhead are catalytically hydrogenated to remove methyl acetylene and propadiene. The hydrogenation process





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is a mixed-phase process licensed by IFP. Methyl acetylene and propadiene are converted to propylene. Hydrogen required for the reaction is supplied from the PSA unit. Hydrogenated C3’s are pumped to the C3 splitter, which consists of two towers: a stripper and a rectifier. The overhead from the stripper is fed to the rectifier. Light ends, a result of the hydrogenation reaction, are removed in the pasteurizing section of the rectifier. Propylene is condensed and returned as reflux. Reflux for the stripper is obtained from the bottom of the rectifier. The stripper is reboiled by circulating quench oil and quench water. The rectifier overhead is condensed by cooling water. The polymer grade propylene product is taken off as a liquid side draw. A propane rich stream is removed as a vapor product from a location two trays above the bottom of the stripper to be recycle cracked in the furnaces. The net bottom liquid is recycled back to the LP depropanizer to remove any green oil produced in the C3 hydrogenation unit. The depentanizer receives a liquid feed from the LP depropanizer bottom. A separation is made between C4’s / C5’s and C6’s. The overhead is condensed against cooling water. LP steam provides reboiler heat. The net overhead product is sent to the C4 /C5 hydrogenation unit and the bottom is combined with the distillate stripper bottom, cooled and sent to OSB as C6+ liquid product.

Hot Fractionation - C4/C5 Hydrogenation Unit The C4/C5 hydrogenation unit selectively converts C5 diolefins to C5 mono olefins using hydrogen from the PSA unit. When C5 diolefins are converted to C5 olefins, C4 diolefins and C4 olefins hydrogenate to C4 saturates which is beneficial for producing ethylene in furnaces when the stream is recycle cracked. The unit consists of a single fixed-bed catalytic reaction system designed by IFP. The C4/C5 product stream is recycle cracked in the cracking furnaces.

Refrigeration The ethylene and propylene refrigeration systems supply refrigeration medium. Vapor from the ethylene compressor is desuperheated and condensed by exchange with all levels of propylene refrigerant and the C2 splitter reboiler. Vapor from the propylene compressor is desuperheated and condensed by exchange with cooling water.

7.4.2 Pyrolysis Gasoline HDT Unit

The raw pyrolysis gasoline obtained from cracker contains diolefins, olefins and paraffins. The gum-forming di-olefins need to be eliminated to make the pyrolysis gasoline stable before it is used for gasoline pool. This is achieved by hydro treating the raw pyrolysis gasoline in single stage.

The raw pyrolysis gasoline including the recycled wash-oil is fed to feed surge drum after being mixed with the C4/C5 heavies and the C4 acetylenics through static mixer. Free water, if any, can be purged from feed surge drum boots. The feed pump raises the feed pressure up to the reaction section pressure. Flow controlled feed is mixed with H2 make-up, and with liquid diluents. The role of dilution is to lower the feed reactivity and thus to allow a smooth control of temperature elevation in reactor first catalyst bed.





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The mixed streams are then charged to the reactor after heating through reactor feed/effluent heat exchanger, reactor inlet temperature is controlled by by-passing part of the reactor effluent around reactor feed/effluent heat exchanger. During start-up periods, the temperature is controlled by means of the steam preheater.

The reactions (diolefins and alkenyl aromatics hydrogenation) occur in mixed phase (mainly liquid) in a fixed bed type reactor. The catalyst is divided into two beds. The overall temperature profile through the reactor is controlled by dilution of feed and by the injection of quench under temperature flow control cascade (TC at the inlet of second bed). Reactor effluent, partly cooled through reactor feed/effluent heat exchanger, is flashed into separator. Part of the liquid is recycled and cooled down as quench or dilution through quench pump, quench cooler and quench trim cooler. The remaining is sent under level flow control cascade to stabilizer. Separator vapor phase is cooled down through separator vapor condenser whose boot liquid is sent back to separator.

Distillation Section

Stabilizer’s purpose is to stabilize the reactor product by eliminating the light components which have been dissolved under high pressure in separator. The overhead vapors of stabilizer are condensed in stabilizer overhead condenser. Stabilizer reflux drum vapor phase is purged to OSBL under column pressure control. Stabilizer reflux drum liquid is pumped by Stabilizer reflux pump as external reflux under flow control reset by level control. Gasoline, the bottom product of the stabiliser column is sent to gasoline storage for sale.

7.4.3 Benzene Extraction Unit

The completely hydrotreated C6-Heart Cut originated from pyrolysis gasoline hydrogenation unit is charged to the 30th tray of the rerun column on flow control, after being preheated in the solvent heated feed preheater. In the rerun column the high boilers (polymers) formed in the upstream hydrogenation unit are removed with the bottom C6+ product, which is routed by pump as a small portion of the feedstock to battery limits, either as hot C6+ cut or as cold C6+ Cut cooled by the C6 Cut Cooler. C6+ product also contains almost all the Toluene from the feedstock and a small amount of Benzene. Therefore the bottom product is fed back to the upstream pyrolysis gasoline separation where the Benzene and Toluene are recovered in the C6-cut distillation column, leading indirectly to no benzene losses in the rerun column. The rerun column operates under vacuum and is equipped with two reboilers. The NMP reboiler is solvent heated and the steam reboiler is heated with LP steam. The overhead C6 cut after condensing in the water cooled condenser is collected in the reflux drum and then charged to tray 21 of the extractive distillation column on flow control. There, Benzene and non-aromatics are separated in the presence of the selective solvent N-Methylpyrrolidone (NMP), charged to the top of the column. By selectively reducing the velocity of Benzene, the NMP together with the benzene is pushed down to the bottom of the extractive distillation column . The non-aromatics and traces of NMP leave the top of the column as vapor product and are charged to the raffinate column.





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The extractive distillation Column also operates under vacuum and is equipped with two reboilers, of which NMP reboiler is solvent heated and steam reboiler is heated with MP steam. The raffinate leaving the top of the extractive distillation column still contains little amount of NMP. This NMP is separated from the raffinate in the raffinate column in order to the meet the raffinate specification on NMP. The NMP stream is recycled back to the extractive distillation column via the bottom of the raffinate column. After condensing in the water-cooled condenser the raffinate is collected in the reflux drum and is sent to battery limits via raffinate pump. The raffinate cooler is designed to lower the temperature of the raffinate to battery limit conditions. The raffinate column also operates under vacuum condition is and is reboiled in the reboiler with MP steam.

The benzene together with the NMP leaves the bottom of the extractive distillation column and is supplied to tray 16 of the benzene stripper on flow control by feed pump. There, benzene and solvent are separated under vacuum condition. At lower pressure and higher bottoms temperature than in the extractive distillation column, here benzene and NMP are separated. The bottom product comprises NMP and about 1% benzene. The overhead benzene product, after condensing in the condenser and collecting in reflux drum leaves the plant as pure product, while the solvent, after heat exchanged in the Reboilers and the solvent cooler is returned to the extractive distillation column. The process configuration ensures maximum heat integration from the hot solvent. The MP steam heated reboilers and the water cooled condenser are attached to the benzene stripper. The column system of the unit is connected to a vacuum system consisting of the liquid ring vacuum pumps and the vacuum drum. The vacuum pumps are operating with solvent from the plant’s solvent loop. Hydrocarbon saturated vapors are scrubbed by the pump’s liquid ring. Liquid and gas are separated in the vacuum drum. The solvent leaves the vacuum system via NMP pump, the cleanness as leaves the top of vacuum drum to the off gas separator.

A small solvent regeneration consisting of the regeneration reboiler with the condenser and NMP regeneration drum as accumulator. During normal operation of the plant the operating of the regeneration is not necessary. Only in case of contamination of solvent with high boilers from the rerun column or other operation the regeneration system may be needed. The plant has a closed slop system with NMP slop drum and hydrocarbon slop drum. Solvent containing systems are drained to the NMP slop drum and pumped to the recycle drum by NMP slop pump. From here the solvent is recycled to the plant. The recycle drum also serves as a run-down vessel which can take the entire solvent content of the plant and also as feed drum when during start-up offspec benzene and raffinate are circulated through the plant. The fresh NMP storage drum ensures to have enough NMP stock to be able to compensate plant losses caused by operational failures or mal operation. The NMP is transferred to the solvent recycle by the fresh NMP pump.





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7.4.4 C4 Hydrogenation Unit

The C4 cut enters the Feed Surge Drum and free water, brought accidentally with the feed, is separated from the hydrocarbon phase by gravitational settling. The pressure of the Feed Surge Drum is controlled by an off gas blanketing system which purges to flare. The off gas used for the blanketing is a part of the purge gas of the reaction section. The C4 cut feed is pumped forward by feed pumps is mixed with the liquid recycle stream and with the hydrogen make-up. The liquid recycle flow rate acting as a diluent is fixed by flow controller, where as the hydrogen make-up is controlled by a flow ratio controller. The amount of excess hydrogen is optimized at required rate in order to minimize purge gas whilst providing adequate hydrogen partial pressure in the reactor. The liquid recycle flow rate is determined by the requirement to restrict the temperature

rise in the C4 hydrogenation reactor, to less than 40C. In order to ensure a good dissolution of the hydrogen in the C4 cut, the mixture flows through a static mixer, before entering the reactor. As the mixture flows down through the catalyst bed of the reactor the C4 hydrogenation reaction takes place in the mixed phase (mainly liquid) and the temperature rises due to the exothermicity of the reaction. In order to prolong the active life of the catalyst, the inlet temperature of the reactor is minimized but it should be sufficient to achieve the required conversion rate of unsaturated hydrocarbons. As the catalyst activity reduces, during the run life, the feed

temperature is increased, from about 60C at Start of Run (SOR), to about 80C at End

Of Run (EOR). The reactor outlet temperature should not exceed 120C in order to

prevent excessive damage to the catalyst. Below 60C the reaction rate is not sufficient to achieve the required conversion, even with fresh catalyst. Temperature in the reactor is maintained from rising by the recycle flow rate and the reactor inlet temperature is controlled by means of a by-pass around the Recycle Cooler. The volume of the gaseous phase in the mixture reduces as hydrogen reacts with the unsaturated hydrocarbons but some of the C4 hydrocarbons are vaporized as the temperature rises. The two-phase mixture leaving the reactor is flashed in the Reactor Effluent Separator. The vapor phase is mainly condensed by the Reactor Effluent Condenser. The condensed liquid produced is separated from the remaining vapor in the Vent Gas Separator and returned to separator; while vapor is purged under pressure control either to the fuel gas system, either to the ethylene plant. Free water is decanted to the closed oily water drain under interface level control in the Vent Gas Separator. The pressure is controlled by a split range system which acts mainly on the flow rate of purge gas. In case of low pressure, some hydrogen make-up gas is used to maintain a sufficient pressure. The vast majority part of collected liquid in the Reactor Effluent Separator is pumped forward by the Recycle Pumps through to the Recycle Cooler and finally mixed with C4 feed.





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7.4.5 LLDPE /HDPE Swing unit

Catalyst preparation

Ziegler Catalyst High activity Ziegler catalyst is used for the production of narrow molecular weight distribution products. This catalyst is supplied ready-to-use by BP.

Polymerisation: Reaction Loop

The reactor is designed to ensure good mixing and a uniform temperature within the fluidised bed. Polymer particles grow within the fluidised bed over a residence time of several hours. Operating conditions within the reactor are mild. The reactor is made from carbon steel and has three main sections:

A bottom section with a gas distributor to ensure homogeneous fluidisation.

A cylindrical section containing the fluidised bed and equipped with catalyst injection and polymer withdrawal facilities.

A conical bulb top section where gas velocity reduces, returning entrained polymer powder particles to the fluidised bed.

The gas leaving the reactor contains unreacted monomer, co monomers, hydrogen and inerts (primarily nitrogen and ethane). Conversion of monomers per pass is proximately 3%. Any fine particles leaving the reactor with the exit gas are collected by cyclones and recycled to the reactor. This greatly reduces fouling in the reactor loop and also prevents product contamination caused by particles formed in the loop, which may have different properties to the target grade. This is one of the reasons why the Innovene process makes such consistently high quality, gel-free products. The gas then enters the first heat exchanger where the heat of polymerisation is removed before passing to the Enhanced High Productivity Separator. This specially designed vessel separates the condensed liquid, typically up to 15% by weight of the stream, from the loop gas, which is fed to the main fluidisation gas compressor. This provides the volumetric flow necessary to achieve the required fluidisation velocity in the reactor. The separated liquid is then pumped into the reactor via proprietary liquid injection nozzles into the heat of the fluidised bed. In the reactor, pressure and gas composition are controlled continuously by varying the flow of feedstock into the reaction loop. The relative proportions of the feedstock are adjusted to meet the specification of the required polymer product. This is achieved using on-line analysers for hydrogen, ethylene and co monomers. A purge is provided to prevent accumulation of inerts. Polymer Withdrawal and Degassing

The polymer powder is withdrawn from the reactor by simple, robust proprietary lateral discharge system and passed on to the primary degasser, where a part of the gas is flashed off, filtered and recycled to the main loop via the recycle compressor. The polymer powder is transferred to the secondary degasser, where most part of the residual hydrocarbon is removed and separated in the cryogenic Vent Recovery Unit. The degassed powder collected in the secondary degasser passes to a purge column, where trace hydrocarbons are removed and any residual catalyst activity is killed.





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Powder is then transferred to the extruder via an intermediate surge bin, mounted directly above the extruder, which allows for routine extruder maintenance. Grade Changes On-line DCS transition control ensures consistently rapid and reliable grade changes. Changes of grade are made quickly and easily, with the minimum loss of throughput and the minimum generation of wide-specification product.

Finishing: Product Blending and Extrusion (Pelletising) Polyethylene powder is transferred pneumatically to the product powder silo. Powder master batch incorporating additives is prepared in mixers or may alternatively be supplied in flexible intermediate bulk containers. The additives are commercially available but the formulations, which are part of Innovene technology, will be disclosed when a licence agreement has been signed. Virgin powder and additives are weigh-fed into the extruder. Pellets are extruded under water and are then dried before being conveyed by air to storage. The pellets conveyed from the pelletising section are homogenised in static homogenisation silos. After homogenisation, the pellets are transferred to storage silos.

7.4.6 High Density Polyethylene

Catalyst feeding PZ Catalyst which is Ti catalyst is used to produce all HDPE grades. AT-Catalyst, which is triethylaluminum, is used as a cocatalyst. PZ-Catalyst preparation PZ-catalyst is charged into PZ feed drum, which has been filled with a specified quantity of hexane, measured by flowmeter. PZ feed drum are kept agitated by means of PZ feed drum agitator respectively. Prior to charging of PZ-catalyst, the flexible connection tube to connect the PZ container to PZ feed drum, which is dried, shall be purged with nitrogen after it is connected. AT- catalyst preparation AT-catalyst is transferred by means of nitrogen pressure from AT container to AT feed drum after a specified quantity of hexane measured by flowmeter has been charged into AT feed drum. AT-catalyst solution is thus diluted to a required concentration. Meanwhile, vent gas in AT-catalyst system is discharged into flare system. PZ-catalyst which has been diluted to a specified concentration in PZ feed drum is fed to each polymerizer by means of PZ feed pump. AT-catalyst which has been diluted to a specified concentration in AT feed drum is fed to each polymerizer through AT feed sub drum by AT feed pump. Polymerization For the polymerization reaction, a low pressure hexane slurry process is employed, using Polymerizers lined up in parallel or series. Ethylene monomer, which is the main raw material, dehydrated hexane for adjusting the slurry concentration and catalyst are continuously fed at specified feed rates to the polymerizers. Hydrogen as molecular weight controller and either propylene or butene-1 for adjusting the density are continuously premixed with ethylene gas, and such mixture is fed into the recycle gas line leading to the polymerizers.





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The heat of reaction is removed by latent heat of hexane, slurry cooling system and cooling by the jacket on the polymerizers. Control of polymer properties, melt flow rate (MFR), density (D) and molecular weight distribution (NNI) of polymer, in the polymerizers is carried out by adjusting polymerization conditions.

Polymerizer recycle gas Ethylene, hydrogen, and either propylene or butene-1 are mixed with polymerizer recycle gas, and fed to 1st Polymerizer / 2nd Polymerizer through the gas injection pipes. The fed raw material gases are thoroughly dispersed by the 3-stage turbine agitator to be dissolved in hexane, and the ethylene gas is polymerized in the presence of catalyst and forms polymer slurry having a specified concentration. At this time, the polymerization pressure is maintained by hydrogen partial pressure. Recycle gas comprising ethylene and hydrogen is blown into the bottom of the polymerizer and ethylene is polymerized during its passage through the adequately agitated hexane phase. More than a half of the heat generated by polymerization is removed by the latent heat of hexane. The recycle gas containing plenty of hexane vapor is transferred to 1st Overhead Condenser (2nd Overhead Condenser), condensed and cooled, and further transferred to 1st hexane Accumulator (2nd Hexane Accumulator) to be separated into condensate hexane and recycle gas. The recycle gas so separated is pressured in 1st Recycle Gas Blower (2nd Recycle Gas Blower) and blown into the bottom of the polymerizer while its flow rate is controlled so as to maintain the polymerization temperature at a specified value. Condensate hexane separated in 1st hexane accumulator is recycled to the polymerizer through 1st Condensate Recycle Pump (2nd condensate Recycle Pump). Part of the condensate hexane is used for flushing at a specified rate in the gas outlet piping for 1st polymerizer (2nd polymerizer). Slurry cooling Polyethylene slurry in polymerizer is circulated through slurry cooler by Slurry Cooler Pump to remove polymerization heat together with recycle gas system and reactor jacket cooling system. Separation and drying section Separation The product slurry is continuously fed through 2nd slurry transfer pump to horizontal-type centrifuge revolving at a high rotating speed, in which polymer is separated by centrifugal force. The product slurry fed to the rotating bowl of centrifuge is pressed to the inside wall of rotating bowl under centrifugal force and separated into product and hexane solvent. The polymer is discharged from the centrifuge by the screw conveyor provided in the bowl in the form of wet cake containing hexane and fed to dryer via wet cake screw feeder. Meanwhile, hexane overflows the weir provided in the bowl and flows into mother liquor drum and then pressured by mother liquor transfer pump so that part of it will be sent back to polymerization section and the remainder will be fed to hexane recovery section. The piping to transfer hexane separated in centrifuge is provided with jacket or steam tracing to prevent the low polymer dissolved in the hexane from solidifying. Drying Steam tube rotary dryer





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Mixed gas consisting of nitrogen and hexane vapor flows through Dryer counter currently with the product. When the product power leaves the dryer, it contains less than 0.2%

volatile matter (as hexane) and its temperature is approx. 100C. Low pressure steam is supplied to the steam tube in dryer as the heat source after its pressure and temperature have been reduced by means of steam cooler Dryer gas circulation system The mixer recycle gas from dryer containing a small amount of fine polymer particles goes into Dryer Gas Scrubber. The circulation liquid in dryer gas scrubbing pumps collects the polymer entrained with the mixed gas. The collected polymer is recovered through dryer gas scrubbing pump into 2nd flash drum, while the liquid level of dryer gas scrubber is controlled by level controller. The mixed recycle gas cooled in dryer gas condenser is pressured by dryer gas blower and is cooled by dryer gas cooler with brine to decrease hexane content in it. The recycle gas from dryer gas cooler is heated by dryer gas heater with low pressure steam. The non-condensable gas which leaves the outlet of purge gas condenser is pressured by off gas compressor and part of it is supplied to the gland of dryer for flushing and the surplus is discharged to the flare system. Pelletizing, storage and packing section Powder hopper The product powder from rotary steam tube dryer is transferred to the nitrogen gas pneumatic powder conveying system through powder rotary valve. The product that is forwarded by powder transfer blower is continuously separated by powder cyclone and dropped into powder hopper. Nitrogen gas separated in powder cyclone is filtered through bag filter to be re-circulated. The very fine powder entrained with nitrogen gas in bag filter is continuously recovered through powder rotary valve into powder hopper. Pelletizing system Polyethylene powder, solid stabilizers, liquid stabilizer and w-stabilizer are fed to homogenizer then to pelletizer having a twin-screw type continuous mixer with gear pump where they are mixed and kneaded. Molten polymer is pushed towards the die by gear pump system. Then the molten polymer is extruded through the die-hole into the cutter bowl through which pellet cooling water is circulated. The extrudate is cut into pellets by the revolving cutter. The resin in the pellet form is transferred to pellet separator with circulated PCW (pellet cooling water). For protection of pellet dryer, a grid is provided PCW Strainer to remove any fused blocks of pellets. The pellets, which passed the grid, are sent to pellet dryer after they are drained on the perforated plate screen. The pellet cooling water separated by PCW strainer and pellet dryer flows into PCW Drum, from which it is re-circulated to the cutter box of pelletizer after pressured by PCW Circulation Pump and cooled by PCW Cooler. Powdery matter suspended in the pellet cooling water is discharged out of the system through the overflow outlet of PCW drum by continuously feeding process water (PW) to PCW drum through the FG. Since this wastewater contains solid particles and stabilizers suspended or dissolved in it, it is transferred to Powder Separator, where solids are separated so that water itself can be disposed of as “oily water”. Product pellets are classified by pellet Vibrating Screen into oversize, normal, and undersized products. Normal size pellets which flow in Pellet Separator Hopper are pneumatically conveyed to the specified silo through Pellet Rotary Valve by pellet Transfer Blower.





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Pellet blending & transfer system Pellet Silos each of which has a capacity of 160 ton has been considered. In order to rectify such fluctuations of quality due to possible variance in the operating conditions at process control, the pellet blending is carried out through transferring the pellet to Packer Hopper. Product pellets are pneumatically conveyed blending to Packer Hopper by Pellet Blending & Transfer Blower of which conveying capacity is 30 ton/hr (max). Packing Pellet transfer capacity from product silos to packing facilities (or shipping facilities) is decided under following assumptions.

1. Product pellets are packed into sacks before shipping. 2. Packing capacity 3. Packing operation

7.4.7 Poly Propylene Unit

Fresh propylene from OSBL is fed through propylene dryer to the reactor along with the required catalyst, co-catalyst, hydrogen and stereo-modifier. For production of two special grades with small ethylene content, ethylene vapor is also fed to the reactor. The polymerization reactors each have a nominal volume of 75 m3 with identical stirrer and drive systems. Polymerization itself is carried out in a gas phase stirred reaction. Heat removal is managed by evaporative cooling. Liquid propylene entering the reactor vaporizes and thereby removes the exothermic reaction energy. Reaction gas is continuously removed from the top of the reactor and filtered. Reactor overhead vapor (“Recycle Gas”) is condensed and pumped back to the reactor as coolant. Non-condensable gases (mainly H2 and N2) in the recycle gas are compressed and also returned to the reactor. The polypropylene product powder is blown out of the reactor under reactor operation pressure. The carrier gas and powder pass into the powder discharge vessel where powder and gas are separated. The carrier gas is routed through a cyclone and filter to remove residual powder, then scrubbed with white oil and sent to compression. Powder from the discharge vessel is routed via rotary feeders to the purge vessels which are operating in parallel. Nitrogen is used to purge the powder off residual monomers. The overhead gas from the purge vessels is sent to a common membrane unit for monomer/nitrogen recovery. As refrigerant for the membrane unit fresh Propylene is used. The recovered nitrogen is sent back to the purge vessels for further use. The condensed monomers from the purge gas are combined with the filtered carrier gas, and then sent to scrubbing and subsequently to carrier gas compression. The PP powder from the purge vessels is pneumatically conveyed by a closed loop nitrogen system to the powder silos. The powder product from these silos is fed to the extruder where polymer powder and additives are mixed, melted, homogenized and extruded through a die plate, which is heated by hot oil. The extruding section is electrically/steam heated. Pelletizing of the final product is carried out in an underwater pelletizer where the extruded polymers - after passing the die plate - are cut by a set of rotating knives. The polymer/ water slurry is transported to a centrifugal dryer where polymer and water are separated. Water is recycled to a pellet water tank, for which demineralized water is used as make-up. The cooled pellets (~60°C) are pneumatically conveyed to the pellet blending silos by an air conveying system. After homogenization in the blending silos the pellets are conveyed to the bagging and palletizing system.





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7.4.8 Butene-1 Unit

The dimerization reaction is activated by the mixing of two specific catalysts. The first one, named T.E.A, is an alkyl-aluminium compound, the second one, named LC 2253 (AXENS proprietary catalyst) is made of a titanium compound and a promotor. Both catalysts are separately stored in diluted T.E.A. day drum and LC 2253 storage drum, filtered and then pumped by metering pumps to the Reactor. The diluted alkyl-aluminium catalyst (T.E.A) and the diluted LC 2253 catalyst are fed to the reactor 32-R-201 through the pumparound loops. In case hexane is used (during start-up), it can be dried before using via Hexane Dryer, before being sent to Washing Hexane Drum. The regeneration of the dryer is carried out with hot nitrogen heated up in Nitrogen Heater. Effluents from regeneration are then sent to flare. Nitrogen Heater ensures also the drying of Pumparound Loops after maintenance with hot nitrogen.

Reaction / Catalyst removal sections The ethylene feedstock coming from Polymer Unit downstream of purification section or directly from cracker is mixed with the unconverted ethylene which is recycled from the recycle column reflux drum. The ethylene stream enters the reactor through a distributor, which improves the dispersion of the ethylene in the liquid. The reaction is exothermic: the heat of reaction is removed by the pumparound coolers installed on recirculation lines around the reactor. The recirculation is maintained by pumparound pumps. The liquid reactor effluent withdrawn from bottom of reactor must be vaporized to remove all the traces of catalysts. Part of the vaporization occurs in the vaporizers by steam condensation; the vapor and liquid phases are separated in the flash drum. The last step of vaporization is achieved through the thin film evaporator which is fed under flow-control reset by the level of the flash drum. The residual liquid is collected in the evaporator receiver drum and feeds under level control the spent catalyst drums which are connected to the flare and steam traced to remove the remaining light compounds. The remaining liquid is either sent to isocontainers and then to incinerator or sent to Fuel Oil. The vapors from the thin film evaporator flow through the evaporator K.O. drum which traps any liquid carry-over. The vapors are then mixed to those got from the flash drum and to the vapor flow from the reactor top. The product, currently stripped from the catalysts, is condensed through the recycle column feed condenser and feeds the recycle column feed surge drum. To stabilize the product before vaporizing it, pure amine is injected to the reactant effluents filters. This prevents any detrimental isomerization of butene-1 into isobutene and butene-2, which could be promoted by temperature downstream, during the vaporization step, without amine injection. The amine, unloaded from drums by the amine unloading pump, is stored in the amine storage drum, and sent to the process by the amine pumps. Distillation section The liquid phase from recycle column feed surge drum is pumped to the recycle column. A partial condensation of its overhead vapors takes place in the recycle column condenser. Due to the presence of methane and ethane in the feedstock, a slight venting to Naphtha Cracker is necessary to prevent from any incondensable vapor accumulation. The vapor (mainly ethylene) is recycled back under pressure control to the reactor feed line. The reboiling of the column is ensured in the recycle column reboiler under temperature control resetting the steam flow rate to the reboiler. The bottom product of the column is routed under flow-control, reset by level, to the butene-1 column.





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The butene-1 column duty is to provide the specification in heavy components of butene-1 product. The butene-1 product is withdrawn as liquid distillate from the column overhead by means of the butene-1 column reflux pumps under level control of the butene-1 column reflux drum. The C6+ cut is withdrawn, at the butene-1 column bottom. The C6+ cut is routed, after cooling through the C6+ product cooler, to the C6+ storage drum. Product drums storage The butene-1 leaving the distillation section can be routed to any of the storage drums "on-spec" drum or an “off-spec” drum after has been cooled down at 40 deg. C in the butene-1 cooler. The butene-1 on-spec product is routed to OSBL storage tank after analysis, by means of the pump. The off-spec product is routed to C4 mix storage, but can also be recycled in the butene-1 column, if it’s content in C6 and heavier is too high. A part of this butene-1 product is used for flushing pumparound pumps, reactor effluent pumps, passivation pumps and ethylene distributor by means of flushing pumps. Another part of this butene-1 is used as carrier or T.E.A. and LC 2253 catalysts to the reactor.





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Chapter 7.5 Utility Systems





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7.5 UTILITY SYSTEMS

7.5.1 Utility Systems for Petrochemical Complex

The utility systems details required to cater to the requirement of petrochemical

complex along with polymer units is detailed below.

Table 7.5.1: Utility Systems

Utility Selected Case

Steam -

Power to be purchased 220 MW

Power from STGs -

Cooling water, M3/hr

(34+3) Nos. cell of 4000m3/hr each + (17+5) pumps of

8000m3/hr each. There are 8 number of cells have been

considered for future.

Inst Air & Plant Air

Compressed Air System to be designed for 27000 Nm3/hr.

For instrument air 3+1 dual bed adsorption based dryers of

capacity 4000 Nm3/hr each are provided. Also 1 nos. 500

Nm3/hr of back up HP air reciprocating compressor

Nitrogen

2 chains of 8600 Nm3/hr of gaseous N2 and liquid

equivalent to be optimized. Vaporizer capacity of 12000

Nm3/hr (steam bath). Liquid nitrogen vessel of 2 X 1900

m3 storage capacity and 6m3, 1 no. of pressurized double

walled storage vessel.

Notes:

1. Deleted.

2. Power import for the expansion facility shall be sourced from the grid. This has

been accounted in OPEX.

3. +It is considered that the existing steam utility boilers shall be used for additional

steam requirement.

4. New ETP for petchem block

5. Total normal raw water requirement for the expansion facility comes to around

3500 m3/hr. Raw water storage for 14 days has been considered.

6. The Petrochem block shall have following Flare systems:

Main Hydrocarbon Flare for Cracker and Auxiliary utility

Sour flare system for Caustic oxidation facility of Cracker + Auxiliary unit

Cryogenic flare for Ethylene storage

Polymer Flare system for all polymer units





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Chapter 7.6 System Details





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7.6 Additional Storage Facilities:

7.6.1 The typical storage facilities considered to cater to the requirement of petrochemical

complex along with polymer units is detailed below.

7.6.2 It is considered that the existing naphtha tanks can be used as feed tank for the

petrochemical complex. Therefore, no additional feed tanks have been considered.

7.6.3 The storage tanks for intermediate feedstock’s and product storage tanks are

tabulated below.

Table 7.6.1: Offsite Storage Tanks

Facility

Storage Capacity m3

( Each pumpable)

Nos. of Tanks/ vessels

Days of storage

Type Remarks

Ethylene 24000 2 7 days DWST Each tank to have submersible pump of 150 M3/hr (2+1).

Vaporizer & BOG system also to be considered as for all ethylene

Tanks

Off- spec Ethylene

1500 1 5 hours Sphere 1+1 pump of 133 M3/hr

Propylene 13000 2 8 days DWST Each tank to have submersible pump of 65M3/hr ( 2+1).

Vaporizer & BOG system also to be considered.

Off-spec Propylene

1870 1 12 hours Mounded Bullet

1+1 pump of 15 M3/hr Centrifugal pump each

C4 mix 2380 4 3 days Sphere 2+1 pump of 65 M3/hr Centrifugal pump each

Off-spec C4 mix

2380 1 1 day Sphere 1+1 pump of 15 M3/hr Centrifugal pump each

RPG 10,000 2 7 days Dome roof + N2

blanketing

Feed to PGH unit. (1+1)X 65 m3/hr Centrifugal pump each

C6 Cut 2200 3 6 days IFR + N2 blanketing

Feed to BZ extraction unit. C6 raffinate shall also be routed here only. (1+1) X 50 m3/hr

centrifugal pump each.

Product Tanks

Benzene 3700 3 16 days IFR + N2 blanketing

Final Product for dispatch

PFO/ CFBS 2500 2 15 days Cone Roof Shall be routed to refinery FO or





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+ N2 blanketing

dispatched as CBFS

Hydrogenated

Pyrolysis Gasoline

9000 2 27 days IFR + N2 blanketing

to be routed to Refinery Gasoline Pool

C9+ Cut 1400 2 14 days Cone Roof + N2

blanketing

shall be routed to refinery

C6+ oligomer

300 2 28 days IFR + N2 blanketing

Shall be dispatched as final product.

Hexene-1 2500 1 - Cone Roof + N2

blanketing


Hexane 500 1 - IFR + N2 blanketing

Shall be utilized in HDPE unit

Pentane 250 1 - Bullet with Nitrogen

Blanketing


Slop 500 1 IFR + N2 blanketing

Crude Tank

60000 1 Floating Roof





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CHAPTER 8.0

ENVIRONMENTAL CONSIDERATIONS





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8.0 Environmental Considerations

For environmental considerations, adequate care will be taken during

conceptualization of the project and in process design to minimize the quantity of

waste produced. In addition, solid, liquid and gaseous wastes generated from various

processes in the complex will be handled in a manner that minimizes their impact on

the environment.

Some of the measures to be taken are as follows:

Solid Waste - It is recommended to dispose off solid waste such as spent catalyst,

tank bottom sludge and ETP sludge in secured landfills outside the complex.

Liquid waste - A fully fledged Effluent Treatment Plant (ETP) has been

considered for the petrochemical complex to treat various liquid effluents

generated in the refinery complex.

Gaseous Effluents - Atmospheric emissions related to the proposed facilities

emanate mainly from the stacks located in various process units and in the CPP.

- SOx Control – The overall SOx emissions from the complex shall be restricted

to the present permissible value of 23.8 TPD.

- NOx Control - Low NOx burners shall be recommended to reduce NOx

emission from all furnaces.





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CHAPTER 9.0 PROJECT IMPLEMENTATION AND SCHEDULE





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9.0 PROJECT SCHEDULE

Overall duration of four years from the start of implementation has been conceived. For a Cracker Complex of this magnitude, which incidentally is also land locked, 45 month schedule for implementation should be envisaged and 3 months should be kept exclusively for commissioning purposes. The key issue, of course, revolves around licensor selection, which often governs the time cycle.

9.1 IMPLEMENTATION APPROACH The following implementation methodology is envisaged: a. Licensor selection shall be carried out on competitive basis and an attempt shall

be made to explore the option of reference units as this will advance the BDEP

and schedule benefit of 2-3 months.

b. For exercising strict control over cost and assuring no slippage of schedule,

Project to be executed on EPCM mode.

c. The mother Cracker, Polymer Plants comprising of Polyethylene, Butene-I and

Polypropylene,and all Utilities & Offsites to be implemented on EPCM route with

defined large packages in the same as may be deemed appropriate.

d. Main package such Furnaces, double wall storage tanks, all utilities packages,

spheres, tankages, etc shall be on EPC route Basis.

9.2 PROJECT MANAGEMENT

9.2.1 General

The Project will be executed on task force concept through a dedicated, well qualified

and experienced team co-located at EIL’s Home Office in New Delhi. The team will

consist of specialists and experts on various aspects of Project namely:

Project Management

Project Scheduling &Control

Cost Estimation

Process Design

Engineering

Procurement, Material Management& Logistics

QA/QC Management

Inspection& expediting

Construction Management

Commissioning Assistance

9.3 PROJECT IMPLEMENTATION STRATEGY

9.3.1 KEY STRATEGIES for FAST TRACK IMPLEMENTATION





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During all phases of the Project, key focus shall be to adhere to HSE and quality

principles of the OWNER and to deliver the Project within cost and schedule. The

following key strategies, innovations shall be adopted to meet the desired objectives.

a. Free issue material to Contractors:

Structural steel, shall be prefabricated and procured along with the supply of

material by the fabricators. Prefabricated structural steel shall be shipped directly to

site and free issued to respective erection agencies. This will facilitate

uninterrupted construction works at site and circumvent delays in procurement of

steel and other bought outs by the civil and structural contractors.

Insulation material for piping shall be procured directly and supplied on FIM basis

to the agency entrusted with mechanical works. This will circumvent delays

associated with delays in procurement of insulation material by the mechanical /

composite agency.

Prefabricated piping spools, platforms, insulations, fire water rings and nozzles,

ladders etc.for the long lead and ODC columns shall be procured so that these can

be installed at grade and columns can be hauled up in dressed up condition.

b. Underground Piping:

Underground piping work shall be minimized to provide overall advantage to

construction activities. This shall be ensured during the conceptual planning stages

for underground facilities itself.

Pre-coated pipes/ epoxy coated fittings for underground facilities shall be sourced

from the competent agencies and shipped directly to site. Coated pipe along with

compatible epoxy fitting shall also be sourced along with the pipes. These shall be

issued as FIM to the site agencies for construction work.

c. Underground Piping Works:In order to minimize the interfaces between various

agencies, laying of pressurized underground piping (CW and FW) shall be included

in the scope of agency entrusted RCC foundation and pavement.

d. Precast manholes and trenches: Precast designs of manholes/ trenches etc.

shall be utilized to the extent possible for fast track construction.

e. Non-plant Buildings:Standard designs of non-plant buildings shall be adopted for

fast track implementation at site.

f. Modularization:Modular designs, wide flanged steel sections and bolted

connections shall be maximized in structural steel designto provide fillip to site

works and separate RFQ shall be released considering the various workloads and

scope shall include supply and fabrication of structural steel.





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g. ODC Consignments

Main emphasis is to ensure that site work is minimized to the extent feasible and

equipment have been identified upfront so that these equipment are brought to site

in single piece ,thereby giving boost in the erection of the equipment in addition to

quality advantage.

h. Pipe racks: Composite pipe rack designs (concrete + steel) shall be followed for

the ISBL pipe rack and structural steel for offsite pipe racks,loading gantry etc. This

philosophy of pipe rack design shall help in obviating requirement of large rolled

steel sections or built-up girders for columns. The offsite pipe racks, however, shall

be of steel design. All pipe racks shall be prefabricated type and assembled at site.

i. Piping spools: Emphasis hall be given to minimize site work and all efforts shall

be made to procurement piping spools to the extent feasible including all HP and

IBR piping.

j. Modularisation: Modularization of pipe racks, skids, Technology structures shall

be considered to give flip to the site activities.

k. Standard Designs: Standard Pipe rack and technological structure designs shall

be made a part of the tender documents and their construction shall be prioritized

to ensure front to mechanical agencies immediately upon mobilization at site.

l. Fireproofing: Fireproofing paint shall be applied on the structures and

Equipment’s to be fire proofed. This will provide tremendous schedule advantage

compared to conventional vermiculite fire proofing.

m. Rationalization of thicknesses: Rationalization of vessels/ columns thicknesses

shall be carried out to reduce variety and provide economy of scale advantages.

n. Drawing front: 40-50% approved for construction (AFC) civil & structural drawings

shall be released to site prior to the mobilization of the contractor. Balance

drawings shall be issued within 8-10 months of award of Contract to the extent

feasible.

o. Extraction of Drawings from 3D Model: 40-50% isometrics along with system

ISOs extracted from the 3D Model shall be made available at site prior to the

mobilization of mechanical contractor.

p. Procurement on bottom line basis: As part of procurement strategy,

procurement on group or on bottom line basis is recommended. This will not only

reduce vendor interface but also provide economy of scale advantages.

q. Spares: Sparing philosophy shall be as per the agreed design basis. Vendors shall

supply mandatory and commissioning spares as part of the order. But two year





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operation and maintenance spares shall also be directly ordered on the vendor in

certain critical cases.

r. Mechanization of construction: Emphasis shall be laid on mechanizing

construction activities, modular concepts & prefabrication & pre-cast methods to

the extent possible so that it adds value in terms of quality, safety & cost

effectiveness. The same shall be suitably covered in tender for construction works.

9.4 PROJECT IMPLEMENTATION SCHEDULE

The detailed bar chart for the project implementation schedule is attached as

annexure-II.





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Annexure-I

Block Flow Diagram





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Annexure-II

Project Implementation Schedule

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