IPCL NAGOTHANE

Presented By

Saurabh Thakur and Monish Sutradhar
INTRODUCTION

Nagothane Manufacturing Division is located
near Raigad, Maharashtra.

It comprises of an ethane and propane gas
cracker and five downstream plants for the
manufacture of polymers, fibre intermediates
and chemicals.

Plants at IPCL Nagothane
Name of Plant Commissioned Year
Gas Cracker 1992
LDPE Plant 1992
Butene-1 Plant 1992
LLDPE / HDPE
Plant

1993
Polypropylene Plant

1990
MEG/Ethylene Oxide Plant

1992
Products and Brands
Company has expanded rapidly and integrated
backwards into other industry sectors, most
notably the production of petrochemicals and the
refining of crude oil.
Operations that span from the exploration and
production of oil and gas to the manufacture of
petroleum products, polyester products,
polyester intermediates, plastics, polymer
intermediates, chemicals and synthetic textiles
and fabrics.
Products and Brands
The Company's operations can be classified
into four segments namely:
Petroleum Refining and Marketing business
Petrochemicals business
Oil and Gas Exploration & Production business
Others
The Company has the largest refining capacity
at any single location.

Products and Brands
The Company is:
Largest producer of Polyester Fibre and Yarn
5th largest producer of Paraxylene (PX)
5th largest producer of Polypropylene (PP)
8th largest producer of Purified Terephthalic
Acid (PTA) and Mono Ethylene Glycol (MEG)




Process Description
Crude Oil Refining
What is Crude Oil
Crude oil, also known as black gold, is a thick, dark
brown or greenish flammable liquid, which is found in
the upper strata of some regions of the Earth's crust
It is a complex mixture of various hydrocarbons,
(mainly, alkanes), along with trances of other
chemicals and compounds (e.g. Sulphur)
When extracted from underground, it ranges in density
from very light to very heavy and in color, from yellow
to black
Crude oil can be categorized as either "sweet crude"
(where the sulphur content less than 0.5%) or "sour
crude," (where the sulphur content is at least 2.5%)


What is Crude Oil
Crude oil must undergo several
separation processes so that its
components can be obtained
and used as fuels or converted
to more valuable products
The process of transforming
crude oil into finished
petroleum products (that the
market demands) is called
crude oil refining

Distillation of Crude Oil
We can separate the components of crude oil
by taking advantage of the differences in their
boiling points. This is done by simply heating
up crude oil, allowing it to vaporize, and then
letting the vapor to condense at different
levels of the distillation tower (depending on
their boiling points). This process is called
fractional distillation and the products of the
fractional distillation of crude oil is called
fractions

Distillation of Crude Oil
A fraction from crude oil can be categorized
into two categories:
Refined Product: A crude oil fraction which
contains a lot of individual hydrocarbons
(e.g. gasoline, asphalt, waxes, and
lubricants)

Petrochemical Product: A crude oil fraction
which contain one or two specific
hydrocarbons of high purity (e.g. benzene,
toluene, and ethylene).
AT THE TOP OF
THE
DISTILLATION
COLUMN
AT THE BOTTOM
OF THE
DISTILLATION
COLUMN
Short carbon
chains
Long carbon
chains
Light molecules Heavy molecules
Low boiling
points
High boiling points
Gases & very
runny liquids
Thick, viscous
liquids
Very volatile Low volatility
Light colour Dark colour
Highly flammable Not very
flammable
Crude Oil Refining
Fractions of Crude Oil & Their Properties
Name
Number of
Carbon Atoms
Boiling Point
(C)
Uses
Refinery Gas 3 or 4 below 30
Bottled Gas
(propane or butane).
Gasoline 7 to 9 100 to 150
Fuel for car
engines.
Naphtha 6 to 11 70 to 200
Solvents
and used in gasoline.
Kerosene (paraffin) 11 to 18 200 to 300
Fuel for aircraft
and stoves.
Diesel Oil 11 to 18 200 to 300
Fuel for road vehicles
and trains.
Lubricating Oil 18 to 25 300 to 400
Lubricant for engines
and machines.
Fuel Oil 20 to 27 350 to 450
Fuel for ships
and heating.
Greases and Wax 25 to 30 400 to 500
Lubricants
and candles.
Bitumen above 35 above 500
Road surface
and roofing.
Chemical Processing
The fractions from crude oil are liable to undergo chemical processing to alter its
structure and thus its properties
The sort of chemical processing employed depends largely on the market demand
Examples of chemical processes are as the following:
Cracking: the process obtaining relatively simple and small hydrocarbon
molecules from the breaking down of large, heavier and more complex
hydrocarbon molecules.
Coking: the process of breaking down bitumen into its fractions (done by
a Coker)
Alkylation: A process where the structure of a hydrocarbon molecule in
one fraction is altered to produce another hydrocarbon molecule with
another structure. In alkylation, compounds with a low molecular weight,
such as propylene and butylene, are mixed in the presence of a catalyst
such as hydrofluoric acid or sulfuric acid
Unification: a process where two or more hydrocarbons are combined to
produce a larger one. The major unification process is called catalytic
reforming and occurs in the presence of a catalyst (platinum, platinum-
rhenium mix) to combine low weight naphtha into aromatics
Treatment Processes
Chemical sweetening, acid treating, clay contacting, caustic washing,
hydro treating, drying, solvent extraction, and solvent dewaxing.
Sweetening compounds and acids desulphurize crude oil before
processing and treat products during and after processing.

Clay Treating
Use clay to soak up and remove unwanted components in petroleum
Dilute the oil with solvent and freeze the oil
During the freezing process, wax will be solidify leaving only the pure oil in
liquid phase
Acid treating
Using concentrated sulphuric acid to convert sludge from the oil
Expensive
SO
2
Treating
Using a very toxic recyclable solvent to remove the worst components in oil

Treatment: The Finishing Touch
Impurities such as organic compounds containing sulphur, nitrogen, oxygen, water,
dissolved metals and inorganic salts must be removed from the distillated and
chemically processed fractions
Treating is typically done by passing the fractions through the following:
a column of sulphuric acid - removes unsaturated hydrocarbons
(hydrocarbons with carbon-carbon double-bonds), nitrogen compounds,
oxygen compounds and residual solids (tars, asphalt)
an absorption column filled with drying agents to dehydrate the fraction
sulphur treatment and hydrogen-sulphide scrubbers to remove sulphur
and sulphur compounds

Today, a major portion of refining involves blending, purifying, fine-tuning and
improving products to meet specific requirements
Example: Refinery workers carefully blend together a variety of hydrocarbons to
make petrol. Moreover to distinguish the various grades of fuel, technicians add
performance additives and dyes. At the end of the production of petrol, the petrol
contains more than 200 hydrocarbons and additives