Panipat Naphtha Cracker Complex

&
Downstream Petrochemicals
An Overview

Presented by
TDVS Gopalakrishna
CPNM, PNC

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

Cost Optimization through Integration

Refinery Olefin Plant Integration Synergy
Stream sharing
Tonnes flow/tonne ethylene

Estimated
3 to 4
ROI
points on
cracker

Synergies

Feedstocks
Refinery

3.0

Naphtha
cracker

0.4
By-products
Stream valueOther
synergy
synergies

Other refinery
streams
(e.g. propylene)

Cracking feeds from low value

refinery products
Low cost octane sources from
cracking by-products
Upgrading refinery streams to
petrochemical quality/
disposition

Total synergy

Shared utilities,
maintenance,
overhead

Drivers for Diversification into Petrochemicals

9 Utilization of refining streams - ready availability of

feed stock
9 HAN for Aromatics
9 LAN for Olefins, supplemented by
FCC C3s and Refinery Gases
9 Pooling of feedstocks for world scale capacity plant
(Panipat, Mathura & Gujarat)
9 Achieving synergy by integration of refinery &
petrochemicals: sharing of facilities and
infrastructure
9 Excellent Potential for Growth

Integration between Refinery and Naphtha cracker

REFINERY

MS
MS

LPG
LPG

SKO/ATF
SKO/ATF

NAPHTHA
NAPHTHA

HAN

HSD
HSD

COKE
COKE

SULPHUR
SULPHUR

LAN

AROMATIC
AROMATIC COMPLEX
COMPLEX

NAPHTHA
NAPHTHA CRACKER
CRACKER

PX
PX

Ethylene
Ethylene

Polymerisation
Polymerisation

Propylene
Propylene

Ethylene
Ethylene
Oxidn.
Oxidn.

Polymerisation
Polymerisation

Benzene
Benzene

PTA
PTA

CBFS
CBFS

Butadiene
Butadiene

HDPE
HDPE

LLDPE
LLDPE

MEG
MEG

DEG
DEG

Poly
Poly Propylene
Propylene

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 - India

PP / PE Capacity Scenario - India

PE Capacity, KTA

PP Capacity, KTA

All Figures in KTA

With 1.2 MMT Capacity IOCL will be second largest Polyolefin Producer in India

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 Drivers

Sector
Packaging
Infrastructure
Agriculture
Consumer Goods
Health Care
Others
Total

Potential by
2013-14
(MMT)
6.2
2.5
0.3
2.3
0.2
1.0
12.5

PackagingwillaccountforhalftheIndianplasticconsumption

PP
PP APPLICATIONS
APPLICATIONS

Furniture &
Housewares

Rigid & Flexible

Pkgg.

Automotive &
Appliances

Medical &
Healthcare

Fibre & Filaments

LLDPE
LLDPE APPLICATIONS
APPLICATIONS

Flexible Packaging

Masterbatch

Roto Molding

Drip Laterals

Extrusion Coating

HDPE
HDPE APPLICATIONS
APPLICATIONS

Houseware &
Oriented Fiber

Material Handling

Pipes

Bulk & Rigid Pkgg.

HM Films

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

Feedstock 2.3 MMTPA Naphtha

Ethylene- 857 KTA

Propylene 650 KTA
Butadiene 130 KTA
Benzene 130 KTA
Naphtha Cracker Unit
Technology : ABB Lummus

PRODUCT SLATE

PRODUCT OUTPUT

000 TPA

LLDPE/HDPE

650

26

PP

600

24

MEG

300

12

DEG

22

LPG/Butadiene

140

BENZENE

125

PYROLYSIS GASOLINE & C9+

318

13

90

235

PYROLYSIS TAR (CBFS)

Fuel & Loss

PROCESS UNITS

UNIT

CAPACITY
(MMTPA)

LICENSOR

0.8 (ETHYLENE)

ABB GLOBAL, USA

0.35

NOVA CHEMICALS, USA

POLYPROPYLENE UNIT

0.6

BASELL POLYOLEFINS,
ITALY

HDPE UNIT

0.3

BASELL POLYOLEFINS,
GERMANY

MEG UNIT

0.3

NAPHTHA CRACKER UNIT

LLDPE/HDPE SWING UNIT

SCIENTIFIC DESIGN, USA

MAJOR UTILITIES AND OFFSITES

ATTRIBUTE

UNITS & CAPACITY

Power

5 GTs:
STGs:

5 x 26 MW = 130 MW
3 x 37 MW = 111 MW

Steam

Utility Boilers
HRSGs

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

: 2 x 410 MT/hr
: 5 x 95 MT/hr

INTEGRATION WITH REFINERY

Both Ways
Utilities (30 MW power, Hydrogen, Nitrogen, LPG, Fuel Oil)

Refinery to PNCP
Naphtha Feed from Refinery/Marketing
C3s from PSU to NCU
Light Distillates (Diesel components)

PNCP to Refinery
C9+ cut, C7-C8 cut, Pyrolysis Fuel Oil

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22

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 Plant

Pyrolysis Heater
S

Gasoline
Fractionator

Fuel Oil
Stripper

Charge Gas
Compressor
1st - 3rd Stages

Process
Water
Stripper

Quench
Tower

ATU,
Caustic &
Water
Wash Tower

Charge Gas
Compressor
4th & 5th
Stages

Condensate
Stripper

W
W

R
W

Fresh Feed

Fuel Oil

Dryer

Demethanizer

Deethanizer

Ethylene
Fractionator
Acetylene
Converter

Propylene
Depropanizer
Fractionator
Methylacetylene &
Propadiene Converter

Debutanizer

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

Polypropylene

300

Spheripol Basell

Dedicated HDPE

300

Hostalen Basell

HDPE / LLDPE Swing

350

Sclairtech - Nova

Polypropylene Plant

Spheripol

No. of Lines Capacity per Line (KTA)

Dedicated HDPE Plant

Hostalen

Technology/ Licensor

Swing Plant

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.

Poly-propylene Unit

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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
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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.

LLDPE/HDPE Swing Unit

R-101

PG
E-105A/B

E-104A/B
CWR

CWS

Hydrogen

PD
P-101/S

E-102

V-103

P-103

P-104

Ethylene

R-102

E-103

V-125A/B

Catalyst

Butene-1 Make-up

Distillation

V-201

Cyclo Hexane Make-up

V-325A/B/C/D/E/F

Catalyst

V-313/14/15/16

V-310
M-305

Solid
Additive

V-119 &
V-120
V-104A/B
V-118
ME-315(Extruder)

To Bagging

V-317

36

Liquid Additive

Salient features of Nova Swing technology

Sclairtech process licensed by Nova chemicals, USA

Solution process-uses cyclohexane as solvent and Butene1/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
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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) Prepn
D-1102 A/B/C

Hexane

TEAL

Cat+Cocat

Reactor: R 1201

Hexane
Butene
Hydrogen
ETHYLENE

Reactor-R120

Post Reactor-R1204
Decanter Vessel
Centrifuge

Cat

Cocatalyst(TEAL) Prpn
D-4103
Mother Liquor

to hexane recovery
Powder Treatment Vessel(D-2301)
PE Cake to screw
conveyor
Screw Conveyor(SF-2101)

PTV
Fluid Bed Dryer(D-2201)
Vibrating screen(S-2203)

3 nos Powder Silos

Pelletizing Powder Bin(D-5101)

5 nos PELLET HOMOGENI

PELLET STORAGE SILOS

ADDITIVES

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 Applications
Film 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 1500 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.

End Uses
of HDPE
20021024-DL-IOC001(Marketing)-4
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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

Niche grades - PP
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 - PE
Bi-Modal HDPE grades for Blow Molding, Pipe & Film Applications
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.

Molecular Weight

MEG Unit

MEG Process
All figures are in MT/HR.
C2H4 30.00%
CH4 38.00%
O2 9.00%

0.27

Ar+N2 23.00%

CG purge

Ballast gas
0.0997

C2H4
22.50
O2 23.44

Lean CG
722.34

Cycle
gas
Compr

Reclaim
Compressor

Recycle w ater
340.84
0.905

EO
Reaction
System

Rich CG
767.99

EO Scrubbing
&
CO2 Removal
System

EO
Stripping &
Acid
Scrubbing

Rich CW
989.8
Lean CW
954.29

318.62

EO
Reabsorption
622.14

Glycol
Feed
Stripper

Glycol
383.21

Reaction

CW Bleed
11.70

13.65

CO2 vent

Process steam

DI
Unit

Reflux

Aldehyde

383.21

MP steam

Drying
MEG product MEG

DEG product
TEG product

TEG

DEG

44.37

Refining
Refining

Refining

Evaporation

15.06
Waste w ater 7.34

2.90

0.16

Poly glycol
0.02

49.28
MHP steam

38.14

2.71

0.12

Glycol

Glycol

Purge

waste
Heat
Boiler

MHP steam

MHP steam

MHP steam

0.24

2.49

28.11

MHP steam 57.39

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
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Logistics
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
IOCs 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

Polymer Warehouse

Size: 80 x 740 m2
Storage Capacity : 54KT

Packaging & Despatch

At a glance

Sampling
/ Testing

Right Grade to

Staging area

Right Customer at
Right Time

HD

SW

PP

Product Analysis & Development

Centre

Product Application & Development Centre - PADC

PADC set up at Panipat (Haryana) near Panipat
Naphtha Cracker Complex
New Grade
development

New Application

Knowledge

development

Management

Marketing

PADC

Technical

Customer

Support to

Relation

Customers

Management

PADC
PLANT

Customers

State of Art Technology Centre with sophisticated Plastic

PADC is an interface between Plant,

Processing & Characterisation equipments

Marketing & Customers

Thank you