2_tdvs gopalkrishna petrochemical
TRANSCRIPT
Presented byPresented byTDVS Gopalakrishna TDVS Gopalakrishna
CPNM, PNCCPNM, PNC
Panipat Naphtha Cracker Complex &
Downstream Petrochemicals
An Overview
Introduction
IOCL in Petrochemicals
• IOCL already into• MTBE• Food Grade Hexane• Linear Alkyl Benzene• Para Xylene• Purified Terephthalic Acid
• Recently entered into• Poly Propylene• Poly Ethylene• MEG
• Immediate Plans• Butadiene/ Styrene Butadiene Rubber
Refinery – Olefin Plant Integration Synergy
Stream sharingTonnes flow/tonne ethylene
Other refinery streams(e.g. propylene)
Cost Optimization through Integration
RefineryRefinery Naphtha Naphtha crackercracker
Feedstocks
By-products
3.0
0.4
Synergies
Stream value synergy
Other synergies
Total synergy
• Cracking feeds from low value refinery products
• Low cost octane sources from cracking by-products
• Upgrading refinery streams to petrochemical quality/disposition
• Shared utilities, maintenance, overhead
Estimated3 to 4 ROI points on cracker
Drivers for Diversification into Petrochemicals
Utilization of refining streams - ready availability of feed stock
HAN for AromaticsLAN for Olefins, supplemented by• FCC C3s and Refinery Gases
Pooling of feedstocks for world scale capacity plant (Panipat, Mathura & Gujarat)Achieving synergy by integration of refinery & petrochemicals: sharing of facilities and infrastructureExcellent Potential for Growth
Integration between Refinery and Naphtha cracker
NAPHTHANAPHTHA
AROMATIC COMPLEXAROMATIC COMPLEX
PropylenePropyleneEthyleneEthylene
NAPHTHA CRACKERNAPHTHA CRACKER
PXPX
ButadieneButadiene
CBFSCBFS
PTAPTA MEGMEG DEGDEG
REFINERY REFINERY
LPGLPG MSMS SKO/ATFSKO/ATF HSDHSD COKECOKE SULPHURSULPHUR
Ethylene Oxidn.Ethylene Oxidn.
PolymerisationPolymerisation
HAN
PolymerisationPolymerisation
Poly PropylenePoly PropyleneHDPEHDPE LLDPELLDPE
BenzeneBenzene
LAN
Opportunities in Plastics
• Low per capita consumption in India
(5.6 kg vs World Avg of 24.5 kg)
• Over next 5 years, CMAI has projected double digit
AAGR of 11% for PP & 12% for PE
Per Capita Polymer Consumption - IndiaPer Capita Polymer Consumption - India
PP / PE Capacity Scenario - IndiaPP / PE Capacity Scenario - India
All Figures in KTA
With 1.2 MMT Capacity IOCL will be second largest Polyolefin Producer in India
PE Capacity, KTA PP Capacity, KTA
Why Plastics?
• Properties can be altered to suit needs
• Good strength/weight ratio
• Tough & Durable
• Chemical/Moisture resistant
• Good heat & electrical insulators
• Easy processibility
• Can be produced in aesthetic colours
• Resuable/Recyclable, etc.
Plastics
• Low per capita consumption in India
(5.6 kg vs World Avg of 24.5 kg)
• Over next 5 years, CMAI has projected double digit
AAGR of 11% for PP & 12% for PE
Polyolefin – Growth DriversPolyolefin – Growth Drivers
SectorPotential by
2013-14 (MMT)
Packaging 6.2Infrastructure 2.5Agriculture 0.3Consumer Goods 2.3Health Care 0.2Others 1.0Total 12.5
Packaging will account for half the Indian plastic consumption
Furniture & Housewares
Rigid & Flexible Pkgg.
Fibre & Filaments
Medical & Healthcare
Automotive & Appliances
PP APPLICATIONSPP APPLICATIONSPP APPLICATIONS
Flexible Packaging
Masterbatch
Extrusion Coating
Drip Laterals
Roto Molding
LLDPE APPLICATIONSLLDPE APPLICATIONSLLDPE APPLICATIONS
Houseware & Oriented Fiber
Material Handling
HM Films
Bulk & Rigid Pkgg.
Pipes
HDPE APPLICATIONSHDPE APPLICATIONSHDPE APPLICATIONS
Overview of Naphtha Cracker Complex
Indian Oil in Petrochemicals
Linear Alkyl Benzene at Gujarat Refinery– Capacity – 120 TMT LAB, UOP Detal Process
– Project Cost - Rs 1200 crore
– Commissioned August 2004
– Successfully operating at over 100% capacity
PX/PTA at Panipat– Capacity 553 TMT PTA (Invista T 10 Technology)/ 370 TMT
PX, UOP Technology
– Project Cost – Rs. 5000 crore
– Commissioned June 2006
– Successfully Operating at 100% capacity
Naphtha Cracker & Downstream Polymer at Panipat– Product : LLDPE, HDPE, PP,MEG, Benzene– Capex : Rs. 14000 Cr.– Commissioned March 2010
Panipat Naphtha Cracker Project
• Ethylene- 857 KTA
• Propylene – 650 KTA
• Butadiene – 130 KTA
• Benzene – 130 KTA
Technology : ABB Lummus
Feedstock 2.3 MMTPA Naphtha
Naphtha Cracker Unit
PRODUCT OUTPUT ‘000 TPA %
LLDPE/HDPE 650 26
PP 600 24
MEG 300 12
DEG 22 1
LPG/Butadiene 140 6
BENZENE 125 5
PYROLYSIS GASOLINE & C9+ 318 13
PYROLYSIS TAR (CBFS) 90 4
Fuel & Loss 235 9
PRODUCT SLATE
UNIT CAPACITY (MMTPA)
LICENSOR
NAPHTHA CRACKER UNIT0.8 (ETHYLENE) ABB GLOBAL, USA
LLDPE/HDPE SWING UNIT0.35 NOVA CHEMICALS, USA
POLYPROPYLENE UNIT 0.6 BASELL POLYOLEFINS, ITALY
HDPE UNIT 0.3 BASELL POLYOLEFINS, GERMANY
MEG UNIT 0.3 SCIENTIFIC DESIGN, USA
PROCESS UNITS
ATTRIBUTE UNITS & CAPACITYPower 5 GTs: 5 x 26 MW = 130 MW
STGs: 3 x 37 MW = 111 MW
Steam Utility Boilers : 2 x 410 MT/hrHRSGs : 5 x 95 MT/hr
Cooling Towers CT-I(NCU): 64000 M3/hr (15+1 cells)CT-II(Polymers): 52000 M3/hr (12+1 cells)CT-III(CPP): 28000 M3/hr ( 6+1 cells)
DM/RO Water 370 M3/hr
Nitrogen 33690 NM3/hr (on BOO basis)
Oxygen 720 NM3/hr (on BOO basis)
Compressed Air 2 x 12000 NM3/hr
ETP 200 M3/Hr, with VOC control
MAJOR UTILITIES AND OFFSITES
20021024-DL-IOC001-(Marketing)-4
22
Both Ways• Utilities (30 MW power, Hydrogen, Nitrogen, LPG, Fuel Oil)
Refinery to PNCP• Naphtha Feed from Refinery/Marketing• C3’s from PSU to NCU• Light Distillates (Diesel components)
PNCP to Refinery • C9+ cut, C7-C8 cut, Pyrolysis Fuel Oil
INTEGRATION WITH REFINERYINTEGRATION WITH REFINERY
Naphtha Cracker Unit
Feed Naphtha
• Naphtha Feed– From IOCL Panipat, Mathura and Gujarat Refineries
• Receipt– Through Pipeline from Panipat & Mathura– Through Tank Wagons from Gujarat - by Pipeline in the long
term
Conventional Design Ethylene PlantPyrolysis Heater Gasoline
FractionatorFuel OilStripper
QuenchTower
ProcessWaterStripper
Charge GasCompressor1st - 3rd Stages
ATU,Caustic & WaterWash Tower
Charge GasCompressor4th & 5th
StagesCondensateStripper
Fresh Feed Fuel Oil
Dryer Demethanizer DeethanizerAcetyleneConverter
EthyleneFractionator Depropanizer
Methylacetylene &Propadiene Converter
PropyleneFractionator
Debutanizer
W
S
W
W W
R
R
Fuel Gas Hydrogen Methane Ethane Ethylene C3 LPG Propylene Gasoline C4 Product
Polymerisation
Types• Addition (e.g., Polyethylenes)• Condensation (e.g., Polyesters)
Production Techniques• Bulk• Solution• Suspension• Emulsion
IOCL Polymer Plants & Technology
Sr. No Plant No. of Lines Capacity per Line (KTA) Technology/ Licensor
1 Polypropylene 2 300 Spheripol – Basell
2 Dedicated HDPE 1 300 Hostalen – Basell
3 HDPE / LLDPE Swing 1 350 Sclairtech - Nova
Polypropylene PlantPolypropylene Plant Dedicated HDPE PlantDedicated HDPE Plant Swing PlantSwing Plant
Spheripol Hostalen Sclairtech
Polypropylene Unit
Poly-Propylene (PP) Unit
– 2 lines x 300 TMT per year/line
– Product slates include:
– Homo-polymers
– Random co-polymers (Ethylene/Propylene)
– Impact co-polymers (Ethylene/Propylene)
– Ter-polymers (Ethylene/Propylene/Butene)
– Capable of producing most of the product grades including
niche/specialty grades.
20021024-DL-IOC001-(Marketing)-4
30
Poly-propylene Unit
Salient features - Basell PP technology
– Spheripol process, licensed by Basell, Italy– Liquid phase process - Polymerisation in liquid propylene
within tubular loop reactor. Heterophasic impact copolymerisation in downstream gas phase fluid bed reactor
– Operating conditions- Pressure: 45/15 bar Temperature 70-80oC
– Easy Control of heat of reaction/Rx Temp., less transition time for grade change over, high yield
– Unreacted monomer is recycled back to Reactor– Catalyst : Zeigler-Natta (Titanium based) catalyst– Co-catalyst: TEAL etc.
PP Product Applications
Homopolymer- Injection moulding, Blow moulding, Sheet, Tape/Raffia, TQPP/BOPP films, Extrusion etc.Random Copolymer- Thin walled Injection moulding, Low heat seal & high transparency films, Blow moulding, Packaging parts, Automotive parts etc.Impact Copolymer- Automotive parts, Appliances, House-ware, Rigid packaging, Thermoforming etc.
20021024-DL-IOC001-(Marketing)-4
33
Swing Unit
Swing (LLDPE/HDPE) unit
– One line of swing unit of capacity 350 TMTPA
– Blocked out operation for production of LLDPE and HDPE products in a solution of Cyclo-hexane
– Product slates include:
– Predominantly commodity polymers
– Specialty / niche grades, as may be required.
36
LLDPE/HDPE Swing Unit
Distillation
V-125A/B
P-101/S E-102 V-103
CWSCWR
E-103
E-104A/B
PG
E-105A/B
V-104A/B
V-119 & V-120
Cyclo Hexane Make-up
P-103 P-104
Hydrogen
EthyleneR-102
R-101
PD
V-118
V-201
Butene-1 Make-up
ME-315(Extruder)
Liquid Additive
V-310
V-317
V-325A/B/C/D/E/F
To Bagging
M-305
V-313/14/15/16 Solid Additive
Catalyst
Catalyst
Salient features of Nova Swing technology
• Sclairtech process licensed by Nova chemicals, USA• Solution process-uses cyclohexane as solvent and Butene-
1/Octene-1 as comonomer.• Reactors are stirred tanks: Broad operating pressure – 160
kg./cm2 and temperature 265 Deg.C.• Easy Control of heat of reaction/Rx Temp., less transition time
for grade change over, high yield• Catalyst : Ziegler-Natta.
Titanium & Vanadium based catalyst.• Cocatalyst – TEAL etc.
Product Applications
LL Films – Garment bags, grocery sacks, liners, blends, trash bags,
cast like film diapers etc.
LL Roto Moulding – Large industrial parts used indoors, large industrial
/ agricultural tanks, shipping drums, toys etc.
LL / HD Injection Moulding – House wares, crates, master batches,
pails, food containers etc.
HD Raffia – Woven Sacks /bags/ nets, Tapes, Filaments etc.
HD Small Blow Moulding – Containers, Small bottles, Squeeze Tubes,
Drum Liners etc.
20021024-DL-IOC001-(Marketing)-4
39
HDPE Unit
HDPE unit
– One line of HDPE unit of capacity 300 TMT per year.
– Product slates include:
» Predominantly specialty / niche grades
» Capable also for commodity grades
– HDPE unit is targeted for producing most of the
niche/specialty grades; however, can cater to the
commodity grades, if market so demands.
SCHEMATIC DIAGRAM SHOWING THE SLURRY PROCESS FOR HDPE PRODUCTION
Cat-Ingredients Hexane
Catalyst(THT/THB/THE) PrepnD-1102 A/B/C
Hexane Cat+Cocat Reactor: R 1201 Reactor-R120 Post Reactor-R1204Hexane Decanter VesselButene Centrifuge
TEAL Hydrogen CatETHYLENE
Cocatalyst(TEAL) PrpnD-4103
Mother Liquor
to hexane recovery
Powder Treatment Vessel(D-2301)
PE Cake to screwconveyor
PTV Screw Conveyor(SF-2101)Fluid Bed Dryer(D-2201)
Vibrating screen(S-2203)
3 nos Powder Silos
Pelletizing Powder Bin(D-5101)
5 nos PELLET HOMOGENIADDITIVES PELLET STORAGE SILOS
EXTRUDER(MX-5101) Pellets drying(S-5103)
Mixing Screw(M-5101)Vibrating Screen(S-5101)
Pellet Sieve(S-5104) PELLETS
Salient features of Basell HDPE technology
• Hostalen process licensed by Basell, Germany
• Slurry process-Polymerization with two reactors in parallel or series. Switching from a single reaction to a reaction in cascade enables producing top quality unimodal and bimodal HDPE from narrow to broad MW distribution including PE-100 pipe. Polymerization occurs in a dispersing medium, such as n-hexane.
• Easy Control of heat of reaction/Rx Temp., less transition time for grade change over, high yield
• Catalyst : Zeigler-Natta (Titanium based) catalyst
• Co catalyst: TEAL, IPRA etc.
Product ApplicationsFilm grade – Blown films with paper like quality, suitable for counter bags, carrier bags&wrapping films Pipe grade – Pr pipes PE-80/100 class, drinking water & gas pipes, waste pipes & sewer pipes-their fittings etc Large BM grade – Universal container grade, vol-appx 1-500 lit; heating oil storage tanks, transport containers Small BM grade – For disinfectant bottles up to 2 lit, tubes for cosmetics, containers from few ml upto 10 lit. Raffia grade – Stretched films & tapes for production of high strength knitted & woven sacks /bags/ nets etc.Injection Molding – For transport & stacking crates, particularly bottle crates.
20021024-DL-IOC001-(Marketing)-4
46
End Uses of HDPE
Niche Grades
Niche grades : PP
High speed BOPP Grade : 1030FGP
Well tailored Polymer Design offers :
• Better process stability
• Higher line speeds
• Good stretchability
Applications :
• Labels
• Food Packaging
• Lamination
• Over Wraps
High Clarity Random Co-Polymer Grade : 2450MG
• Higher Flow
• Excellent Clarity
• Good Rigidity
• Low Warpage
Applications :
• CD / DVD Covers
• Food Containers
• Thin-Walled products
Niche grades - PP
Super Impact Co-Polymer Grades : 4040MG / 4080MH / 4120MN
• Good Processability
• High Impact (> 150 J/m)
• Excellent balance of impact & stiffness
• Good surface properties
Niche grades - PP
Bi-Modal HDPE grades for Blow Molding, Pipe & Film Applications
Molecular Weight
Customer expectations :• Higher working pressure• Reduced wall thickness• Improved ESCR (Pipe & BM)
Product Properties depends upon • Mol. Weight & Density of the resin• Placement of co-monomer on right type
of molecular chain
Advantages of Bi Modal PE :
• Co-monomer incorporation on high molecular weight chains
• Increase in molecular weight without sacrificing processability
• Bi-modal HM film grades with dart impact up to 14 gm/mic.
Niche grades - PE
MEG Unit
All figures are in MT/HR.
C2H4 30.00%CH4 38.00%O2 9.00% 0.27
Ar+N2 23.00% CG purgeBallast gas
0.0997 Lean CG C2H4 722.34 Recycle water
22.50 340.84 O2 23.44 0.905
Rich CG Rich CW767.99 989.8 318.62
Lean CW 622.14 383.21954.29
CW Bleed11.70 13.65
383.21
Aldehyde Purge
MP steam 49.28
MEG product MHP steamDEG product 38.14 44.37 15.06
TEG product 2.71 Waste w ater 7.34 MHP steam 57.390.12 2.90
0.16Poly glycol
0.02 MHP steam MHP steam MHP steam0.24 2.49 28.11
Process steam
Reflux
CO2 vent
EOReactionSystem
EO Scrubbing & CO2 RemovalSystem
EO Stripping &Acid Scrubbing
EOReabsorption
Cycle gas Compr
DI Unit
Glycol FeedStripper
Glycol Reaction
Glycol
Evaporation
Glycol
Drying
MEG
RefiningDEG
RefiningTEG
Refining
wasteHeatBoiler
Reclaim Compressor
MEG Process
Salient features of SD MEG technology
• Process licensed by Scientific Design, USA
• Gas phase Ethylene Oxidation reaction on Silver catalyst
• Operating Conditions: Temp: 220-270 deg C
Pressure: 20 kg/cm2g
• Non-catalytic Adiabatic Hydrolysis Reaction of Ethylene
Oxide to Glycols (about 145 deg C; 17 kg/cm2g)
20021024-DL-IOC001-(Marketing)-4
55
Infrastructure
• Warehouse: 740 M x 80M- Can store 50000 MT plus
• 15 Automatic Bagging & Palletizing machines
• 50 Loading bays - capable to handle twice the Daily produce
• Exclusive truck parking of 75,000 Sq-m paved area with support services
• IOC’s own Inland Container Depot at Panipat
• PWD road connectivity with highway (Delhi-Amritsar)
• Road transporters to reach product any where in India
• Arrangements with CONCOR for door delivery by rail in containers
Logistics
Size: 80 x 740 mSize: 80 x 740 m22
Storage Capacity : 54KTStorage Capacity : 54KT
Polymer Warehouse
Sampling/ Testing
Staging area
HD SW PP
Right Grade to
Right Customer at
Right Time
Packaging & Despatch –At a glance
Product Analysis & Development Centre
PADC set up at Panipat (Haryana) near Panipat
Naphtha Cracker Complex
PADCPADC
PLANTPLANT
MarketingMarketing
CustomersCustomers
New Grade development
Knowledge Management
Customer Relation
Management
Technical Support to Customers
New Applicationdevelopment
PADCPADC
PADC is an interface between Plant,
Marketing & CustomersState of Art Technology Centre with sophisticated Plastic
Processing & Characterisation equipments
Product Application & Development Centre - PADC
Thank youThank you