Annexure-1

Brief on Production and manufacturing process

ONGC Petro additions Ltd (OPaL), a joint venture Company of Oil and Natural Gas Corporation Limited (ONGC), Gas Authority of India Limited (GAIL) and Gujarat State Petroleum Corporation Ltd (GSPCL) is setting-up a grass root Petrochemical complex based on dual feed i.e., C2/C3/C4 & Naphtha, at Dahej Special Economic Zone (SEZ), Gujarat state. The proposed complex shall consist of dual feed Cracker of 1100 KTPA capacity to produce petrochemical feedstock for various downstream Basic Polymer block. The implementation of proposed petrochemical complex is about to complete and is expected to start its operation during the year 2015. The proposed petrochemical complex consists following Process Units (Licensed):

i. Dual-Feed Ethylene Cracker unit 1100 KTPA Ethylene ii. Pyrolysis Gasoline Hydrogenation (PGH) unit 543 kTPA iii. Butene-1 unit 35 kTPA iv. Linear Low density Poly-ethylene (LLDPE)/

High density Poly-ethylene (HDPE) Swing unit 2 x 360 kTPA v. High density Poly-ethylene (HDPE) Dedicated unit 1 x 340 kTPA

vi. Poly-propylene (PP) unit 1 x 340 kTPA vii. Butadiene Extraction unit (BdEU) 115 kTPA

viii. Benzene Extraction Unit (BzEU) 150 kTPA ix. Styrene Monomer unit 160 kTPA x. Styrene Butadiene Rubber (SBR) 140 kTPA

The Dual feed cracker uses C2, C3, C4 extracted from C2+ Extraction plant in the upstream and

Low Aromatic Naphtha & Aromatic Rich Naphtha from ONGC’s plant at Uran and Hazira respectively as feedstock. Ethylene, Propylene, mixed C4 stream, Raw Pyrolysis Gasoline (RPG), Carbon Black Feed Stock (CBFS), Hydrogen gas and Fuel gas are produced as a result of cracking. Hydrogen gas and fuel gas are reused within the complex.

Generated Ethylene from the cracker will be used within the complex in the separate downstream Butene-1 and polymer units to produce Linear Low Density Polyethylene (LLDPE), High Density Polyethylene (HDPE). These products will be sold to market for further processing to obtain various products as per application.

Generated Propylene from the cracker will be used in the separate downstream polymer units to produce Polypropylene (PP). This products will be sold to market for further processing to obtain various products as per application. Excess propylene will be sold to market.

Generated mixed C4 stream from cracker will be used to extract 1-3-Butadiene through Butadiene Extraction unit and Butadiene raffinate will be recycled back to Cracker. This extracted Butadiene will be used to manufacture Styrene Butadiene Rubber in a separated polymer unit. In absence of SBR plant extracted Butadiene will be sold to market.

Generated Pyrolysis Gasoline stream from the cracker will be hydrogenated in Pyrolysis Gasoline Hydrogenation unit (PGHU) to produce C6 stream, heavy aromatic C9 stream and Hydrogenated Pyrolysis Gasoline. This Generated Hydrogenated Pyrolysis Gasoline (HPG) and

C9 stream will be sold to market for further end uses and generated C6 stream will be sent to the Benzene Extraction Unit (BzEU) for recovery of Benzene. Fully hydrogenated C5 cut is recycled back to the cracker.

Generated C6 stream from the PGHU will be charged into the Benzene Extraction Unit from where C6 raffinate is recycled back to the cracker. Benzene extracted is sent as feed to Styrene Unit to produce Styrene monomer. Some of the styrene produced is used in Styrene Butadiene Rubber (SBR) unit and rest will be sold to the market. In absence of Styrene Monomer plant extracted Benzene will be sold to market.

Generated CBFS from the cracker will be sold out to the market for further usage.

Hydrogen gas generated is used internally in PE, PP unit, PGHU units. Fuel gas generated is used for internal consumption.

Process Flow schematics of the complex as well as separate unit are given in below figures.

i. Process Flow Diagram for Initially Proposed Petrochemicals Complex :

ii. Process Flow Diagram – DFCU (dual feed cracker unit ), Butadiene Extraction unit (BdEU),

Pyrolysis Gasoline Hydrogenation Unit (PGHU) and Benzene Extraction Unit (BzEU) :

Py Gas to Storage

CBFS

C4

Feed Preheating

Cracked Gas

Comprn

Precooling & Drying

Ethylene Refrigerant

Cycle

C2H4/C2H6 Seperation

C1/C2 Sepern

Low Temp. Section

C2 Hydrogn

C2/C3 Sepern

Cracking Furnace

Units

C3 HydrognC3/C4 Seperation C3 Stripping

Fuel Gas System

Caustic Scrubbing

Oil Fractionation BdEU

PSA Plant

Water Scrubng C4/C5

Seperation

Process Steam System

Gasoline Stabilization

C3H6/C3H8 Seperation

BzEUPGHU

Ethylene

Propylene

Butadiene

LAN

ARN

Benzene

C2

C3

Hydrogen

C9+ to Storage

iii. Process Flow Diagram OF Pyrolysis Gasoline Hydrogenation (PGH) unit :

iv. Process Flow Diagram of Butadiene Extraction Unit (Bd EU) :

v. Process Flow Diagram of Benzene Extraction Unit (BzEU) :

vi. Process Flow Diagram of Butene -1 Unit:

vii. Process Flow Diagram of PP Unit:

viii. Process Flow Diagram of LLDPE/HDPE Swing Unit

ix. Process Flow Diagram of HDPE Unit :

x. Process Flow Diagram of Styrene Monomer unit :

xi. Process Flow Diagram Styrene Butadiene Rubber Plant :

Along with above mentioned product manufacturing units OPaL considered to install under

mentioned offsite facilities:

i. Utility Facilities (Power Receiving & Distribution system, Raw water system, DM water system,

Cooling water system, Compressed Air (Instrument & Plant) System, Fuel gas system, Inert Gas

system, Steam and Power Generation system, Condensate & condensate polishing system,

Emergency power system, Air conditioning for control room and administrative building, Air

pressurization system for substation, External and internal illumination, Utility & product

Distribution piping, etc..)

ii. Offsite Facilities (Tankage/Storage facility, Resin Silos and Bagging facility, Effluent Treatment

system with R.O., Flare and Relief system, Chemical Storage, Catalyst storage, Fire Fighting system,

Gas detection system, Fire detection and alarm system, DCS based control system, UPS, DC power

and distribution system, Storm water drains, Security & surveillance system, Loading & Unloading

system, Product dispatch facilities up to Dahej Port, Offsite piping insulations, Plant buildings

(including Administrative Building), Cross country pipeline from Hazira to Dahej for ARN together

with pumping & metering facilities at Hazira, etc..)

iii. Infrastructure Facilities (Internal roads and main approach roads, Communication facilities,

Construction water and distribution, Construction Power & distribution, Non-plant buildings,

Security Barracks and Guard houses, Warehouse facilities, Guest-house, Construction office

building, Canteen building, Emergency D.G. House, Health centre, Drainages & culverts, etc..).