C

INDUSTRIAL TRAINING REPORT

TRAINING MENTORMR. KAMAL PAHWA

PREPARED BY: DIPTA BHANU BAKSHI BTECH-CHEMICAL ENGG. UNIVERSITY SCHOOL OF CHEMICAL TECHNOLOGY GURU GOBIND SINGH INDRAPRASTHA UNIVERSITY NEW DELHI

CONTENTS:

A.

INTRODUCTION

1. NAME OF ORGANISATION 2. BRIEF ABOUT ORGANISATION 3. ANNUAL TURNOVER 4. PLANT LOCATION 5. MANPOWER 6. SUPPLY CHAIN SYSTEM 7. PROCESS FLOW DIAGRAM (PANIPAT REFINERY)

B. 1. 2.

PRODUCTS BRIEF DESCRIPTION & BLOCK DIAGRAM ECONOMICS OF MANUFACTURED PRODUCTS

C. 1.

SAFETY MEASURES GENERAL SAFETY REGULATIONS

D. PROJECT

1. 2. 3.

CALCULATION OF EFFICIENCY OF FIRED COMBUSTOR PRE HEATER CALCULATION OF EFFICIENCY OF PTA DRYER CALCULATION OF EFFICIENCY OF ROTARY VACUUM FILTER

E. BRIEF DESCRIPTION OF INDIAN OIL INDUSTRY 8. OIL PIPELINES

PANIPAT REFINERY
Brief description about organization:
INTRODUCTION: Panipat Refinery happens to be the 7th and the youngest Refinery of Indian Oil, Indias premiere oil refining and marketing company, which is currently ranked at the 125th position in Fortunes Global 500 ranking. Refinery started its journey as a grass root plant of capacity 6 MMTPA at a capex of 3868 crores, with a objective to cater ever growing demand of middle distillates (mainly diesel) in north and north west India. In view of continuous growth of demand in this region (in last fiscal year India has witnessed about 5.8% increase in demand of petroleum products) capacity was later enhanced to 12 MMTPA in the year 2006(at a capex of 4165 crores) and was further increased to 15 MMTPA in 2010. With commissioning of 15 MMTPA revamp of Panipat refinery Indian oil has become a largest refiner of the country with a market share of 35% of the total refining capacity of the country. Refinery has procured global, state-of-the art technologies from world renowned licensors like Axens (formerly IFP); France, Haldor-Topsoe; Denmark, UOP & ABB Luumas; USA, Stone & Webster; USA and Delta Hudson-Canada. With northward movement of crude oil prices, refining margin worldwide has come under severe pressure post 2007. In order to protect the declining bottom lines, integration of petroleum refineries with petrochemicals has been found to b a lucrative option. In line with the international trend, Panipat refinery has also added two mega petrochemical complexes to its fold- a aromatic complex (PX PTA) of capacity 0.553MMTPA (PTA output) at a capex of 5104 crores in the year 2006 and olefinic complex (naphtha cracker) of capacity 0.8MMTPA (in terms of ethylene output) at a capex of whooping 14439 crores in the year 2010. With commissioning of these two mega

petrochemical complexes, Panipat is now the 3rd largest integrated complex in Asia. In addition to sharing of feed streams from refinery, complexes operate in synergy with each other as lot of intermediate and final products from individual units are shared among other consumers within the complex. PX PTA will produce 3, 53,000 MT/annum Paraxylene and 5,53,000 MT/annum PTA from the complex. PTA is the basic raw material for producing Polyester Staple Fibre (PSF), Polyester Filament Yarn (PFY) and other resins. PTA is produced from Paraxylene. One of the by products from the complex is 21,000 tonnes per annum Benzene. Post commissioning of naphtha cracker to cater to huge feed demand a new pipeline called Mathura-bijwasan-Panipat pipeline of capacity was laid for transporting feed naphtha from Mathura refinery of Indian oil to Panipat refinery. In relentless effort of maintaining its stature as an environment friendly refinery PR has started consumption of RLNG (regasified liquid natural gas) in its fuel system. For uninterrupted supply of R-LNG to PR complex a dedicated pipeline of capacity 10 MMSCMD, this is called DADRI-PANIPAT pipeline. CRUDE INPUT: It receives crude oil from Vadinar and Mundra Ports in Gujarat coast. The refinery is designed for processing both indigenous & imported crude oil. The refinery processes high sulphur crudes mostly from Middle East countries like Saudi Arabia, Iran, Iraq, Dubai, Kuwait. And low sulphur crudes are mostly procured from north and west African countries like Angola, Nigeria, equatorial guinea. Also some very light, sweet crudes are procured from far east countries like Malaysia, Indonesia and Brunei. Apart from the above refinery processes indigenous crudes like Bombay high, panna-mukta and was the first Indian refinery to process mangala crude discovered by cairn energy India ltd. in barmer district of Rajasthan. Since crude is received from the western coast, two pipelines have been connected to the refinery- one is salaya Mathura pipeline which handles both high sulphur and low sulphur crudes and the other is mundra Panipat pipeline which handles only high sulphur heavy crude and caters dedicatedly to Panipat refinery. Its pertinent to mention in this context that Panipat refinery processes the highest quantity of high sulphur crude amongst all Indian oil refineries (approx 75%) . PLANT LOCATION: Lying 80 KMs north of Delhi on the Grand Trunk Road build by SherShah (d.1545); Panipat in the State of Haryana, otherwise famous for cotton milling, wool, glass and manufacture of electrical appliances, can today boast of Indian Oils Panipat Refinery. Located 20 KMs from the town of Panipat amidst lush emerald fields, Indias most modern refinery was built at a

cost of Rs. 3868.00 Crores and has an installed capacity of six million metric tonnes per annum. ANNUAL TURNOVER: Indian Oil Corporation Ltd. is Indias largest company by sales with a turnover of USD 73 Billion and profit of USD 1.7 billion for the year 2010-11(in previous fiscal turnover was USD 58.2 billion and profit was USD 2.33 billion). Above figure indicates that in current market scenario, for PSU refiners, physical performance not necessarily always translate into increased profit.

SUPPLY CHAIN SYSTEM

Pipeline transportation being the least cost mode of transport, approx 49.6 % of total products generated in the refinery are transported to marketing depots through pipelines. Panipat is connected to complex northern region pipeline network of Indian oil through various pipelines as mentioned below: 9. PANIPAT-AMBALA-JALANDHAR PIPELINE (PAJ) of capacity 3.5MMTPA. 10.PANIPAT-SANGRUR-BATHINDA PIPELINE(PB) of capacity 1.5 MMTPA 11.PANIPAT-REWARI PIPELINE (PR) of capacity (this pipeline transports only E IV grade products meant to be supplied to NCR. 12.PANIPAT-DELHI PIPELINE (PD) of capacity (major chunk of the total ATF consumption of NCR is supplied by Panipat refinery by this pipeline. 13.PANIPAT-NABHA-JALANDHAR PIPELINE(PJ) of capacity (this is a a dedicated pipeline for LPG and Indias first LPG transport pipeline) Of the rest 32.4% is transported through rail wagons and 18% through TTs.

Figure 1: Typical Supply chain of Petroleum business

REFINERY BLOCK FLOW DIAGRAM

MANPOWER & AREA: Highly Skilled manpower is the backbone of this refinery. The complex has Total 2231 number of employees, of which 1140 belong to the executive category and 1091 in workmen category.It has the lowest manpower of all refineries in the region with similar capacities It is spread over an area of 4253 acres (this includes township & 756 acres for PNCP).

Products from Refinery:

From April 2010 Panipat refinery has been supplying E III & E IV grade HSD in the market, a manifestation of strong commitment to compliance of environmental norms. Configuration of the refinery was planned with the objective of maximizing diesel. Of the total products

45% is HSD as can be seen from the below mentioned product slate. Because of tight govt control on the prices of diesel, realisation on this product is less. Therefore PRs GRM takes a hit as it is the largest producer of HSD. This indicates challenges lying ahead for thorough exploration of alternative means for maximization of GRM. Approximate product slate is indicated below: (SOURCE: annual operation report 2010-11)

Products TMT Crude oil 15000 LPG 600 MS 1200 Naphtha 974 SKO/ATF/MTO 293 Diesel 4650 Bitumen 300 Sulphur 130 Coke 720

Productions of these products also include stream shared materials received from petrochemical plants.

PRODUCT BLOCK FLOW DIAGRAM:

SPECIFICATION OF PRODUCTS:
LIQUEFIED PETROLEUM GAS (LPG)

(LPG COOKING GAS) Weathering (Volatility, evaporation temp. for 95% vol. at 760mm Hg pressure) Copper strip corrosion for 1 hr at 38oC +2oC max Not worse than 1b

MOTOR SPIRIT (MS) E III (PETROL FOR VEHICLES) RON(Research Octane Number) Sulphur Benzene 91 < 150ppm < 1%

AVIATION TURBINE FUEL (ATF)

(FUEL FOR AVIATION) Density at 15oC Final boiling point Flash point Freezing point 0.775 - 0.840 g/ml 240oC max 38oC min -47oC min

SUPERIOR KEROSENE OIL (SKO)

(KEROSENE OIL FOR COOKING) Flash Point Recovery at 200oC 38oC min > 50% Vol min

HIGH SPEED DIESEL (HSD) E III

(DIESEL FOR VEHICLES) 95% Vol Recovery at Sulphur sulphur HSD E IV 96 RON GASOLINE (GASOLINE) 360 oC max 350 ppm max 50 ppm

(FUEL FOR AVIATION) RON(Research Octane Number) > 96

NAPHTHA (NAPHTHA)

(NAPTHA FOR FERTILISERS) Density at 15oC Final Boiling Point Aromatics & Olefins 0.66 - 0.75 g/ml 180oC max < 10/0.5 % Vol

BITUMEN (BITUMEN)

(BITUMEN TAR FOR ROADS) viscosity grade 10(VG 10) viscosity grade 30(VG 30) 60 poise at 135 deg C 250 poise at 135 deg C

MINERAL TURPENTINE OIL (MTO)

(MTO FOR PAINT INDUSTRIES ETC.) Colour Final Boiling Point +25 Saybolt 205oC max

Expansion Projects At Panipat Refinery

The project to increase the capacity of Panipat Refinery to 15 MMTPA has already been implemented, which takes into account fuel quality requirements in the country.

1. PXPTA at Panipat Refinery: The project envisages putting up of facilities at Panipat Refinery for separation of paraxylene from 110-150 degree C Naphtha cut by pooling the feedstock from Mathura and Panipat Refineries. The project considers facilities like splitter, reformer, extraction plant, and toluene disproportion plant besides utilities for production of para-xylene. Project Cost: Rs. 5104 crores commissioning: August 2005 On implementation, the production of para-xylene/PTA aids in import substitution and value addition besides having an export potential.

2. Panipat Refinery Expansion by 6 MMTPA: The proposed facilities comprise an additional CDU of 6 MMTPA along with Hydrocracker, Delayed Coking Unit, Diesel Hydrotreater, Hydrogen Plant and Sulphur Recovery Plant. Project Cost: Rs. 4165 crores Commissioning: October 2005 To meet the growing deficit of petroleum products in the high demand Northwest region of India.

Apart from these, there are pipeline projects linked to Panipat refinery expansion. Indian Oil Corporation Limited (IOCL) at Panipat consists of various units. Among them major ones are:

14.Atmospheric and Vacuum Distillation Unit(AVU) 15.Continuous Catalytic Reformer Unit(CCRU) 16.Visbreaking Unit(VBU) 17.Hydrogen Generation Unit(HGU) 18.Resid Fluidized Catalytic Cracking Unit(RFCCU) 19.Once Through Hydrocracker Unit(OHCU) 20.Full conversion hydrocracker(HCU) 21.Diesel Hydrotreatment unit (DHDT) 22.Diesel Hydrodesulphurization Unit(DHDS) 23.Motor Spirit Quality Improvement Unit(MSQ) 24.Delayed Coker unit(DCU) 25.Amine Regeneration Unit(ARU) 26.Sour Water Stripper Unit(SWSU) 27.Bitumen Blowing Unit(BBU) 28.Sulphur Recovery Unit(SRU) 29.PX-PTA unit 30.Naphtha Cracker Unit(NCU)

1. Atmospheric and Vacuum Distillation Unit(AVU)

AVU is designed to process 15 MMTPA Bombay High and Arab Mix crudes in blocked out operation in AVU I while Arab mix and Kuwait crudes in AVU II. AVU, a fully integrated unit, consists of the following sections. Crude Distillation Unit, Vacuum Distillation Unit, Naphtha Stabilizer, Naphtha Splitter, Mineral Turpentine Oil Splitter, LPG Vaporizer, and Treating Units for Fuel Gas, LPG and Naphtha. AVU I was mechanically completed in February 1998 and trial operation of the various sections started in phases starting from May 1998. The Unit was commissioned on 2nd October 1998. AVU II was commissioned in may06.

2. Continuous Catalytic Reformer Unit(CCRU) M/s. IFP, FRANCE licenses the CCRU. This unit is designed to process 0.65 MMTPA of SR Naphtha from Arab mix and/or Bombay High crude. This unit consists of Naphtha Hydro Treating, Catalytic Reforming and Catalyst Circulation and Regeneration Sections. Reformate generated from this unit is the principal constituent of MS pool.

3. Visbreaking Unit(VBU) Visbreaking Unit (VBU) is designed to process 0.4 MMTPA Arab mix vacuum residue. This unit is a soaker Visbreaker, which reduces the viscosity of feed at lower temperature because of higher residence time. The unit was mechanically completed in March 1998 and the trial operation started in July, 98. The unit was commissioned on 29th October 1998.

4. Hydrogen Generation Unit(HGU) Old Hydrogen Generation Unit is designed for the production of 38,000 Metric Tonnes of Hydrogen per year, whereas the new HGU is designed for the production of 140,000 Metric Tonnes of Hydrogen per year. Both the units are licensed by M/s. Haldor Topsoe-Denmark, which consists of Desulphurization, Reforming and CO-conversion sections. With PSA system of M/s. UOP-Belgium, Hydrogen requirement with purity of 99.9% vol. produced.

These units have been provided to cater the Hydrogen requirement of Hydrocracker unit as well as Diesel Hydro Desulphurization Unit (DHDS). The unit was mechanically completed in November 1998 and was commissioned on 11th February 1999.

5. Resid Fluidized Catalytic Cracking Unit(RFCC) This is the first Resid Fluidized Catalytic Cracking Unit (RFCC) unit in the country; capacity of the unit is 0.85 MMTPA. The unit is licensed by M/s. Stone and Webster Engineering Corporation Limited-USA. The unit was mechanically completed in November 1998 and commissioned on 28th January 1999.

6. Once Through Hydrocracker Unit(OHCU) The capacity of the unit is 1.9 MMTPA and is the highest capacity Hydrocracker Unit in the country. This unit is designed to convert vacuum gas oil to middle distillates and FCC feed stock. The unit is licensed by M/s. UNOCAL/UOP-USA and is designed to operate at a pressure of 162 kg/cm2g and 4200C. It has 3 reactors, each weighing about 500 Metric Tonne and wall thickness of 256mm to take care of this high pressure. The unit was mechanically completed in November 1998 and was commissioned on 26th April99. 7. Diesel hydrotreatment unit (DHDT) It has been designed for the Production of Euro-III and Euro IV grade Diesel with Cetane improvement by 6 Units and Sulphur reduction from 1.56% to 0.005% (50 ppm). It has a Capacity of 3.5 MMTPA and was commissioned in Dec05. 8. Diesel Hydrodesulphurization Unit(DHDS) DHDS unit has been designed to reduce the sulfur content in High Speed Diesel to less than 0.05% wt. The process technology for this unit was built within the record time on LUM SUM TURN key (LSTK) basis by M/s. L&T. The capacity of the unit is 0.7 MMTPA. The unit was mechanically completed in March99 and commissioned on the 12th July.

9. Motor spirit quality improvement unit(MSQ)

It has been set up for the improvement of MS quality to meet Euro-III/Euro-IV equivalent fuel quality norms w.e.f. 1st April 2010. Euro-IV is used in Metros and identified cities whereas Euro-III is used in Rest of India.

10. Amine Regeneration Unit(ARU) ARU is designed to process Hydrogen Sulfide rich amine from amine Absorption units and recover amine after releasing the acid gas to the Sulphur Recovery Unit. This unit was mechanically completed in February99 and was commissioned on 6th March99. 11. Sour Water Stripper Unit(SWSU) The unit consists of 4 Sour Water Stripping Units, one for the sour water from the Hydrocracker unit and the other for the sour water from the remaining units. This unit was mechanically completed in December98 and was commissioned on 15th February99.

12. Bitumen Blowing Unit(BBU) Bitumen Blowing Unit (BBU) has been designed to produce 2 grades of Bitumen, viz.: VG 30 & VG 10 from vacuum residue of high Sulfur Crudes. The capacity of the unit is 0.5 MMTPA. This unit was mechanically completed in March 1998; trial run of the unit was taken in July 1998 and was commissioned on 12th December 1998. 13. Sulfur Recovery Unit(SRU) SRU is designed to process Hydrogen Sulfide rich acid gas recover elemental sulfur. The unit was designed by M/s. EIL for a capacity of 230 tonnes per day 96% recovery efficiency, which has further been revamped to 450 tonnes per day and 99% recovery efficiency based on the process technology of M/s. Delta Hudson, Canada. This unit was mechanically completed in March99 and was commissioned on 30th March99.

14. PX-PTA Unit

It Produces Paraxylene from heart-cut naphtha. It gets its Feed from Panipat and Mathura Refinery. This complex consists of conglomeration of 8 units involving Reforming, Fractionation units, Solvent Extraction, Isomerisation, Trans-alkylation, Disproportionation processes etc. It has a capacity of 553 TMTPA with PX production of 363 TMTPA (feed to PTA unit). It was commissioned in May06.

15. Naphtha Cracker Unit(NCU) This Project was approved in Dec06 with a Capex of Rs. 14,439 Cr. It was then commissioned in Nov09. It requires a Feed Stock of Surplus Naphtha which gives Value added products like HDPE, LLDPE, PP, MEG. The refinery's highlights include: 31. Zero discharge of effluent water. 32. The presence of four ambient air monitoring stations that were in place well before the refinery was in use. 33. It is an eco-friendly refinery, as indicated by a green belt outside it which is 14 kms long. 34.Flare gas recovery system. 35.Highest energy efficiency among all refineries. MBN, which is an indicator of energy efficiency (the lower, the better), is lowest and currently a benchmark in indian refining industry.

SAFETY MEASURES
GENERAL SAFETY REGULATIONS: Because of hazardous nature of operation in the refinery, which handles large volume of hydrocarbons of extreme inflammable nature a comprehensive safety system has been put

together to take care of in emergency. Some of the salient features of the safety system is as follows: 36.SIREN SYSTEM: In case of any emergency the same is communicated through sirens of three different types. 37.Major fire: a wailing type siren, shall be blown for two minutes at a stretch. 38.Disaster: three times wailing type siren with a gap of one minute in between. 39.All clear: two minute straight siren. 2. PROHIBITED MEASURES: Some items, which have been identified to have potential risk for battery area operations have been banned in the operational area. These are: 40.Matchbox 41.Lighter 42.Mobile phones 43.Laptop 44.Pen drives Apart from the above, all people working inside the operational area are compulsorily required to wear helmets and safety shoes.

PREVENTIVE ACTION AGAINST DAMAGE BY CHEMICALS: 45.Inside the battery area of individual units visual boards have been erected with MSDS(material safety datasheet) of relevant chemicals written on them. 46.Operators handling corrosive chemicals are provided with PVC jackets and gum boots. 47.Safety showers have been provided near all major chemical handling areas. FIRE WATER NETWORK: 48.The total fire water network is designed as per OISD(oil industry safety directorate) 117 norms. 49.Maintenance of 7 kg/sqcm gauge pressure is ensured in the fire water network for which pressure gauges have been provided at different locations. 50.To take care of power failure emergency, apart from electrical motors two diesel operated jockey pumps have been provided in the fire water network.

51.Fire water sprinklers have been provided in identified areas like hot pumps, hydrogen bullets, and LPG Horton spheres. These are automatic water spray systems actuated by heat detection.

FIRE FIGHTING MEASURES: Panipat refinerys fire fighting system is designed to handle two simultaneous major fires and for these following arrangements have been made:

52.Mobile equipments: foam tenders (7 numbers), foam nurser (4 numbers), DCP tender (2 numbers), emergency rescue tender(1 number), hydraulic platform(1 number), rim seal protection in all floating group tanks. 53.Automatic hydrocarbon detectors near identified equipments handling very volatile hydrocarbons. 54.Hydrant risers at all technological platforms. 55.HVLR (high volume long range monitors) in units of various capacities (750/1000/2000/4000 GPM).

SAFETY PREPAREDNESS: 56.Toxic gas detectors in units as per OISD and licensor guidelines. 57.Low temperature gas tight suits for handling cryogenic substances. 58.Regular mock drills, both onsite and offsite. 59.Compulsory fire fighting training for all employees, both at induction level as well as at mid job level. 60.Regular touch with mutual aid partners i.e. other industries in the vicinity and fire brigade of local administration. 61.Emergency exits at different locations as per guidelines of external safety audit committee. 62.Assembly points at different locations for gathering of employees under emergency situations. 63.Imparting safety training- both operational and shutdown safety-to all contractor personnel and truck drivers.

MOTIVATION FOR ADHERING TO SAFETY NORMS: 64.Monthly awards to maximum near-miss incident reporters. 65.Regular hosting of safety quizzes. 66.Hosting of Safety slogans and safety poster making competitions.

Make safety a habit

ABOUT INDIAN OIL INDUSTRY: An Introduction to Oil Industry in India After the Indian Independence, the Oil Industry in India was a very small one in size and Oil was produced mainly from Assam and the total amount of Oil production was not more than 250,000 tonnes per year .

This small amount of production made the oil experts from different countries predict the future of the oil industry as a dull one and also doubted India's ability to search for new oil reserves. But the Government of India declared the Oil industry in India as the core sector industry under the Industrial Policy Resolution bill in the year 1954, which helped the Oil Industry in India vastly.

Oil exploration and production in India is done by companies like ONGC or Oil and Natural Gas Corporation and OIL who are actually the oil companies in India that are owned by the government under the Industrial Policy Rule. The National Oil Corporation during the 1970s used to produce and supply more than 70 percent of the domestic need for the petroleum but by the end of this amount dropped to near about 35 percent. This was because the demand on the one hand was increasing at a good rate and the production was declining at a steady rate.

Oil Industry in India during the year 2004-2005 fulfilled most of demand through importing oil from multiple oil producing countries. The Oil Industry in India itself produced nearly 35 million metric tons of Oil from the year 2001 to 2005. The Import that is done by the Oil Industry in India comes mostly from the Middle East Asia.

The Oil that is produced by the Oil Industry in India provides more than 35 percent of the energy that is primarily consumed by the people of India. This amount is expected

to grow further with both economic and overall growth in terms of production as well as percentage. The demand for oil is predicted to go higher and higher with every passing decade and is expected to reach an amount of nearly 250 million metric ton by the year 2024. Some of the major companies in the Oil Industry in India are: 67. Oil India Ltd. 68. Reliance industries 69. Bharat Petroleum Corporation Limited 70. Hindustan Petroleum

Top 50 Oil and Gas Companies of India S.No Site 1.

Indian Oil Corporation

2.
ONGC

3.
Bharat Petroleum

4.
Reliance Petroleum Limited

5.
Essar Oil Limited

6.
Gas Authority of India

7.
Hindustan Petroleum Corporation

8.
Aban

9.

Oil India Limited

10.
Tata Petrodyne

11.
Bongaigaon Refinery

12.
Gas Projects (India) Private Limited

13.
Hindustan Oil Exploration Company Limited

14.
India LPG

15.
IBP Co. Limited

16.
Lubricants India

17.
Oil Gas India

18.
Petrosil Group

19.
Shiv-Vani Universal

20.
Kochi Refineries Limited

21.
Niko Resources Limited

22.
Assam Oil Company Limited

23.
Balmer & Lawrie & Co.

24.
Bombay High

25.
Mangalore Refinery and Petrochemicals

26.
Petronet LNG Limited

27.
Gujarat Oleo Chem Limited

28.
Geo Global Resources

29.
Cairn Energy

30.
Charottar Gas Sahkari Mandli

31.
Essar Oil India

32.
Gujarat Gas Company Limited

33.
Gujarat State Petroleum Corporation

34.
HOECL

35.
Jubiliant Empro

36.
JHON ENERGY

37.
Pankaj Petroleum Corporation Limited

38.
Piyush Petroleum Corporation Limited

39.
Prize Petroleum Corporation Limited

40.
Hardy Oil and Gas Limited

41.
Selan Exploration Tech Limited

42.
M/S Kunj Forgings Private Limited

43.
SledgeHammer Oil Tools Private Limited

44.

Aeromarine

45.
Jindal Drilling and Industries Limited

46.
Parveen Industries Private Limited

47.
Punj Lloyd Limited

48.
Alfa Pumps and Systems

49.
Gumpro Chem Drilling Fluids

50.
Indiana Gratings Private Limited

INTRODUCTION TO PTA UNIT

PTA ( PURIFIED TEREPHTHALLIC ACID ) White Crystalline Powder having Mean particle size in 90-110 Microns. Raw Material for Polyester fibers & Yarns, Bottles and Films. PTA is produced from PX , which is obtained from Mixed Xylenes from Aromatic Rich naphtha Cut. Polyster is produced by polycondensation polymerization of PTA and MEG . Other Polyester Raw Material MEG ( Mono Ethylene Glycol ) is made by Ethylene produced by Naphtha / Gas Cracking.

PTA : USES PSF (Polyester Staple Fibre) PFY (Polyester Filament Yarn) Polyester resins PET

PX-PTA AT PANIPAT REFINERY Integration with petrochemicals Value addition using Naphtha from Mathura & Panipat refineries No PTA plant in Northern region (Significant fiber consumption area) - Location advantage.

REACTION CHEMISTRY

The overall reaction is extremely quick and typical reactor product only contains 0.2 to 0.3% of 4-carboxybenzaldehyde (4CBA), the major impurity.The slowest step in the above series of reactions is the oxidation of paratoluic acid; hence this acid is the intermediate present in the largest quantity.

MAIN PATH FOR CONVERSION OF FEED TO PRODUCT

CHEMISTRY IN PURIFICATION UNIT

PURIFICATION UNIT The main sections of the Purification Plant are Feed Preheating & Reaction, Crystallization & Solid/ Liquid Separation, Product Handling & Storage, and Mother liquor & Vent Treatment. Crude Terephthalic Acid (CTA) product from the Oxidation Plant contains a small quantity of impurities which must be removed before the material can be used in the manufacture of polyester products. This is achieved in the Purification Plant by selective catalytic hydrogenation of an aqueous solution of CTA at elevated temperature and pressure. The CTA from intermediate storage is reslurried in water, then pumped at high pressure through a series of preheaters where it is heated by flash steam and hot oil, dissolving all the solid. Hydrogen is added at the reactor inlet, and the solution then passes through a bed of palladium/carbon hydrogenation catalyst. The solution is then passed to a series of five crystallizers, where the pressure is reduced in stages, flashing off steam and precipitating PTA. To achieve the required product purity, the slurry is centrifuged at pressure , then the cake discharged to a drier, then the powder is pneumatically conveyed to batch storage for analysis. From batch storage, the powder is conveyed to product storage, from where it is transferred to packing or container filling.Mother liquor from the pressure centrifuges is let down to atmospheric pressure, and is then further cooled, before passing through a filter to recover PTA. Continuous vent streams from the Purification Plant pass to a scrubber to remove solids and recover additional heat.

TYPICAL PROCESS HEATER

Calculation of Efficiency of Fired Combustor Pre Heater Without Air Pre heater

Considerations during calculation: a. 100 % combustion b. 2.5 % Radiation losses c. Sample calculation done for 17.06.08 time 8:00 AM d. Air Pre heater not employed

Calculation of Total Enthalpy of Fuel Oil & Fuel Gas Fuel Oil Enthalpy (H1): Fuel Oil Flow = 571.29 kg/hr Fuel Oil Calorific Value = 9500 kcal/kg H1= LHVFO * FLFO Where H1 = Fuel Oil Enthalpy (kcal/hr)

LHVFO = Fuel Oil Calorific Value (kcal/kg) FLFO

=

Fuel Oil Flow (kg/hr)

H1 = 571.29 * 9500 H1 = 5427225 kcal/hr

Fuel Gas Enthalpy (H2): Fuel Gas Flow = 497.10 kg/hr Fuel Gas Calorific Value (LHV) = 10980.00 kcal/kg H2 = LHVFG * FLFG

Where H2 LHVFG FLVG = Fuel Gas Enthalpy (kcal/hr) = Fuel Gas Calorific Value (kcal/kg) = Fuel Gas Flow (kg/hr)

H2 = 497.10 * 10980.00 H2 = 5458158 kcal/hr

Then, Total Enthalpy HTotal : Q1 = H1 + H2

Q1 =5427225 + 5458158 Q1 = 10885413 kcal/hr

Calculation of Total Heat Absorbed by Off Gas The Off Gas Flow can be evaluated by two methods: (1) Using the Expander Curve as Expander Power & Off Gas inlet temp and pressure known (2) Using the material balance around the equipment block shown based on the given flow rate and other parameters available.

Using the Expander Curve as Expander Power & Off Gas temp and pressure known:

The Off Gas flow as per the Expander Curve is 140 T/hr. Q2A = FO * CPT * (T2-T1)

Where Q2A = Total Heat absorbed by Off Gas (kcal/hr) FO = Flow of Off Gas (kg/hr) CPT = Specific Heat of Off Gas (kcal/kg deg C) T1 = Inlet Temp of Off Gas (Deg C) T2 = Outlet Temp of Off Gas (Deg C) Hence Q2A = 140000*0.24*(389.59-143.02) Q2A = 140000*0.24*246.57 Q2A = 8284752 kcal/hr Therefore , Efficiency = Q2A / (0.975*Q1A) * 100 = 8284752 / (0.975*10885413) = .7806 * 100 = 78.06 %

Using the Material Balance around the equipment block shown based on the given flow rate and other parameters available.

Material Balance over HP Absorber FR = FD + FO ------------------ (1) Where, FR = Off Gas Out from Reactors A/B FD = Off Gas to Driers FO = Off Gas to FCPH Then, F O = F R - FD

Material Balance over Reactors A/B FR = FA + FB ----------------------- (2) Where, FR = Off Gas out from Reactors A/B FA = Off Gas out from Reactor A FB = Off Gas out from Reactor B

Then, FA = (% w/w O2)FA + (% w/w CO2)FA + (% w/w CO)FA + (%N2)FA Where , In Air = 76.69 % N2 w/w = 23.30 % O2 w/w As N2 is inert & not involved in the reaction. 76.69 % of AA = (% N2) * FA Where AA = Air to Reactor A 0.7669 * 111.25 =N2 % in Off Gas Hence N2 in Off Gas = 85.31 TPH

From Plant Data O2 = 4.26%, CO2 = 1.56%, CO = 0.49% FA = 0.0426FA + 0.0156FA + 0.0049FA + 85.31 ( 1 0.0426 + 0.0156 + 0.00449 ) FA = 85.31 FA = 85.31/0.98 FA = 87.05 TPH Similarly for Reactor B,

76.69 % of AB = (% N2 ) * FB Where AB = Air to Reactor A 0.7669 * 111.5 = N2 % in Off Gas Hence N2 in off gas = 85.5 TPH FB = (% w/w O2)FB + (% w/w CO2)FB + (% w/w CO)FB + (N2%) O2 = 3.31% , CO2 = 1.44% , CO = 0.52% (1 0.0331 + 0.0144 + 0.0052)FB = 85.5 FB = 173.41 TPH

Material Balance over FCPH, FR = FD + FO FD = Off Gas to Drier 35 TPH as per Flow meter. FR = 173.41 TPH Then, F O = F R - FD = 138.41 TPH = 138410 kg/hr

Therefore,Total Heat absorbed by the off gas from the equation Q2B = FO * CpT * (T2-T1) = 138410 * 0.24 * (389.59 143.02) = 8190660.89

Then Efficiency, = Q2B / Q1 * 100 Where = Efficiency (%)

Q2B = total heat absorbed by off gas (kcal/hr) Q1 = total enthalpy (kcal/hr) = 8190660.89 / (.975 * 10885413) = 0.7700 = 77.00%

Calculation of Efficiency of Fired Combustor Pre Heater With Air Pre heater

Considerations during calculation: a. 100 % combustion b. 2.5 % Radiation losses c. Sample calculation done for 20.06.11 time 11:00 AM d. Air Pre heater employed

Calculation of Total Enthalpy of Fuel Oil & Fuel Gas Fuel Oil Enthalpy (H1): Fuel Oil Flow = 390 kg/hr Fuel Oil Calorific Value = 9500 kcal/kg H1= LHVFO * FLFO Where H1 = Fuel Oil Enthalpy (kcal/hr)

LHVFO = Fuel Oil Calorific Value (kcal/kg) FLFO

=

Fuel Oil Flow (kg/hr)

H1 = 390 * 9500 H1 = 3705000 kcal/hr

Fuel Gas Enthalpy (H2): Fuel Gas Flow = 414 kg/hr Fuel Gas Calorific Value (LHV) = 10980.00 kcal/kg H2 = LHVFG * FLFG Where H2 LHVFG FLVG = Fuel Gas Enthalpy (kcal/hr) = Fuel Gas Calorific Value (kcal/kg) = Fuel Gas Flow (kg/hr)

H2 = 414 * 10980.00

H2 = 4545720 kcal/hr

Then, Total Enthalpy HTotal : Q1 = H1 + H2

Q1 =3705000 + 4545720 Q1 = 8250720 kcal/hr The Off Gas flow as per the Expander Curve is 134 T/hr. Q2A = FO * CPT * (T2-T1) Where Q2A = Total Heat absorbed by Off Gas (kcal/hr) FO = Flow of Off Gas (kg/hr) CPT = Specific Heat of Off Gas (kcal/kg deg C) T1 = Inlet Temp of Off Gas (Deg C) T2 = Outlet Temp of Off Gas (Deg C) Hence Q2A = 134000*0.24*(383.6-141.8) Q2A = 134000*0.24*241.8 Q2A = 7776288 kcal/hr

Therefore , Efficiency = Q2A / (0.975*Q1A) * 100 = 7776288 / (0.975*8250720) = .966 * 100 = 96.6 %

Thermal Efficiency of PTA Dryer = Heat of Evaporation of Liquid in Cake Total Heat Load in dryer Heat of Evaporation of Liquid in cake = Sensible Heat + Latent Heat Sensible Heat = MW*CP*(TC TF) Latent Heat= MW*W = (MW - MWP)*CPW*(TB TF) + (MW - MWP)*W QT Where QT = Total Heat Load, kcal/hr MW - MWP = Amount of Water Evaporated, kg/hr MW = Initial Moisture Content, kg/hr MWP= Moisture Content at Falling Rate Drying Zone, kg/hr W= Latent Heat of Water, kcal/kg CPW= Specific Heat of Water, kcal/kgC TB= Boiling Point of Water, C TF= Temp of Feed, C Total Heat Load QT = QH + QC+ QF QH= Heat Load at Heating Zone, kcal/hr QC= Heat Load at Constant Rate Drying Zone, kcal/hr QF= Heat Load at Falling Rate Zone, kcal/hr

Heat Load at Heating Zone: QH = QS +QL QS=MPTA*CPS*(TB - TF) QL=MW*CPW*(TB - TF) Where QS= Solid Enthalpy, kcal/hr

QL= Liquid Enthalpy, kcal/hr MPTA= Dry PTA Powder Rate, kg/hr CPS= Specific Heat of Dry PTA, kcal/kgC

Heat Load at Constant Rate Drying Zone: QC=(MW - MWC)*W Where MWC= Moisture Content at Constant Rate Drying Zone, kg/hr Heat Load at Falling Rate Zone: QF = QFS + QFV+ QFL QFS= MPTA*CPS*(TO TB) QFV=(MWC - MWP)*HT QFL=MWP* CPW*(TO TB) Where QFS= Heat Load for solid in Falling Rate Zone, kcal/hr QFV= Heat Load of Evaporation in Falling Rate Zone, kcal/hr QFL= Heat Load of Unevaporated Liquid in Falling Rate Zone, kcal/hr HT=Enthalpy Difference, kcal/kg TO=Temp at dryer outlet, C

Critical Moisture Content at Constant Rate Drying Zone : MWC =( MPTA + MWC)*0.005

Critical Moisture Content at Falling Rate Drying Zone : MWP =( MPTA + MWP)*0.001

Sample Calculations: Given Data: MPTA=74.79 TPH Ms=14.96 TPH (Steam Rate) TF= 100C TO=127.31C TB=100C W=540 kcal/kg CPS=0.24 kcal/kgC CPW=1 kcal/kgC Tin=148C (Steam Inlet Temp) Tout=100C (Steam Outlet Temp) Hin=2746.14 kJ/kg (From steam table) Hout=606 kJ/kg Hence, HT ,steam= 2746.14 606 = 2140.14 kJ/kg = 511.139 kcal/kg (From steam table)

Calculations: Calculation of QT : QT = HT,steam*MS = 511.139*14960 =7646639.44 kcal/hr

Note: As per the design of dryer moisture goes down from 15% to .5% to .1% means from Heating Zone to Constant Rate Drying Zone to Falling Zone.

Calculation of MWC: MWC =( MPTA + MWC)*0.005 MWC = 375.83 kg/hr Calculation of MWP: MWP =( MPTA + MWP)*0.001 MWP =74.86 kg/hr Calculation of QH: QH = QS +QL QS= MPTA*CPS*(TB - TF) = 74790*.24*(100 100) =0 kcal/hr QL= MW*CPW*(TB - TF) = MW *.57*(100 100) =0 kcal/hr QH = 0+0 = 0 kcal/hr

Calculation of QC: QC= (MW - MWC)*W = (MW 375.83)*540 = 540 MW 202948

Calculation of QF: QFS= MPTA*CPS*(TO TB) = 74790*.24*(127.31 100) = 490203.576 kcal/hr HT= H1 H2 =2696 419.5 =2276.5 kJ/kg =543.7 kcal/kg QFV= (MWC - MWP)*HT =(375.83 74.86)*543.7 =163639.41 kcal/hr QFL= MWP* CPW*(TO TB) = 74.86*1*(127.31 100) = 2044.43 kcal/hr QF = QFS + QFV+ QFL = 655887.4126 kcal/hr Calculation of MW: QT = QH + QC+ QF 7646639.44 = 0 + 540 MW 202948 + 655887.4126 MW = 13321.7 kg/hr

Calculation of : = Heat of Evaporation of Liquid in Cake Total Heat Load in dryer = (MW - MWP)*CPW*(TB TF) + (MW - MWP)*W QT = (13321.7 74.86)*1*(100 100) + (13321.7 74.86)*540 7646639.44 = 0.9355 = 93.55%

Hence the Thermal Efficiency of the PTA Dryer is 93.55%

CALCULATION OF EFFICIENCY OF ROTARY VACUUM FILTER

Rotary Vacuum Efficiency calculation based on Acetic Acid removal

Flow Chart for material balances

Efficiency of rotary vacuum filter

= Total Acid in Mother Liquor Total Acid going in Rovac = M.LACID FACID + ST Where, FT = Total feed to Rovac, TPH FACID = Acetic acid in Rovac Feed, TPH M.LACID = Acetic acid in Mother Liquor, TPH

ST = Total solvent to Rovac, TPH VM = Total volatile material in CTA Dryer, TPH Solid Recovery = Total CTA from Rovac outletTotal CTA from Rovac feed

Solid Recovery = CCTA CT

Where, CCTA = Total CTA in Cake Feed to Dryer, kg/hr CT = Total CTA in Rovac feed, kg/hr.

Assumptions made: 1. Solids in mother liquor is taken as 0.3% (based on lab analysis). 2. To ensure the feed rate to rotary vacuum is true we use the pump Curves. For first pump: Load = 51kW Flow = 260 m3/hr (from curve) Density of fluid slurry = 1.1317 kg/m3 Therefore, Flow in kg/hr = 260 X 1.1317 = 295 tonnes/hr For second pump, Load = 25kW Flow = 180 m3/hr Density of fluid slurry = 1.1317 kg/m3 Flow in kg/hr = 203 tonnes/hr

Plant data:
1) 2) 3) 4) 5)

Solvent feed to Rotary Vacuum A (ST1) = 6.73 TPH Solvent feed to Rotary Vacuum B (ST2) = 8.73 TPH Mother liquor out (Mliqour) = 107.64 TPH Total CTA production from dryer (CCTA) = 66.43 TPH Total Volatile Material in CTA dryer (Cacid) = 8.65 TPH

Total solvent = Solvent in Rotary Vacuum A + solvent in Rotary vacuum B ST = ST1 + ST2 = 6.73 + 8.73 = 15. 46 TPH

Total feed to rovac = Cake out from rovac + mother liquor - solvent feed from Rovac

FT = total feed to Rovac, kg/hr CD = total cake feed to CTA dryer, kg/hr MLIQUOR = Mother liquor out from rovac, kg/hr ST = total solvent feed to rovac, kg/hr CCTA = total CTA in cake feed to dryer, kg/hr MCTA = CTA in mother liquor, kg/hr CT = total CTA in Rovac feed, kg/hr MV = volatile material in CTA dryer, kg/hr CCTA = CCTA + CLOSS = 66.27 + 0.1646 = 66.43 Now,

MCTA = MLIQUOR * 0.003 (as per lab analysis) = 107.64 *0.003 = 0.32292 TPH

M.LACID = MLIQUOR - MCTA = 107.64 0.32292 = 107.31708 TPH

CT = CCTA+ MCTA = 66.43 + 0.32292 = 66.76292 TPH

CD = CT + CACID = 66.75 +8.65 = 75.4 TPH

FT = CD + MLIQUOR - ST = 75.4 + 107.64 15.46 = 167.58 TPH

FACID = CACID + M.LACID - ST = 8.65 + 107.317 15.46 = 100.83

= Total Acid in Mother Liquor

Total Acid going in Rovac = M.LACID FACID + ST = 107.317100.83+15.46 = 107.317116.29 = 0.9228 = 92.28%

So the Rovac efficiency based on the volatile liquid removal is 92.28%

Now, Solid Recovery = amount of CTA from Rovac cake outlettotal CTA in

Rovac feed
Solid Recovery = CCTA CT = 66.4366.76 =0.995 = 99.50%

Solid recovery is 99.50%

ECONOMICS OF PTA PRODUCTION

MAJOR COST COMPONENTS IN CONVERSION OF PX TO PTA 1. STEAM 2. ACETIC ACID 3. FUEL 4. POWER = 30 % = 26 % = 25 % = 10 %

5. CATALYST AND OTHER CHEMICALS= 7 % 6. OTHER UTILITIES = 2 %

PTA QUALITY PARAMETERS

PTA PRODUCT CRITICAL PROPERTIES

4CBA

(Typical analysis 12 ppm)

In typical PTA, the concentration is significantly lower than the guarantee value of 25 ppm. This is due to high conversion of 4CBA to pToluic acid in the pure plant reactor. The low levels in PTA confirm that the pure reactor is successfully reducing the 4CBA from oxidation plant. The pure plant Pd / C catalyst is nominally run in the pure plant for about one year. During this time, the catalytic activity decreases. There are ways in which this loss of activity can be monitored such as pure reactor pressure increases / UVT decreases. Another of these measures is an increase in 4CBA in PTA. Analytical method Capillary Electrophoresis Para Toluic acid Typical analysis 110 ppm Para Toluic acid is mainly present in PTA as the waste product from the reduction of 4CBA in the pure reactor, but it can also be made in the pure reactor by reduction of Terephthalic acid. Its detrimental effect is known be a chain stopper. The pToluic acid value is used in the guarantee as a marker of quality Analytical method Capillary Electrophoresis Powder Colour Typical analysis 1.1

In order to produce consistent colour measurements, the PTA is formed into a plaque with a flat surface by compressing a known weight of powder under pressure. The plaque is then analysed by calculating the amount on light reflected and comparing this with standard white and black tiles of known colour.Analytical method Colorimetric Water Typical analysis 0.1 % . The concentration of water in PTA is used as a marker of the drier performance. Typically the concentration of water is less than 0.2 % Analytical method Karl Fischer titration