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

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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.

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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.

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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.

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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.

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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)

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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