FEASIBILITY REPORT FOR RECOVERY OF STYRENE,...

FEASIBILITY REPORT FOR

RECOVERY OF STYRENE, MIXED XYLENE / TOLUENE

INDIAN OIL CORPORATION LIMITED PANIPAT NAPHTHA CRACKER COMPLEX, INDIA

REPORT No. A202-RP-0241-0001 VOLUME 1 OF 1 AUGUST 2012

This report is prepared for M/s IOCL and it is for use by M/s

IOCL or their assigned representatives/organizations only.

The matter contained in the report is confidential.


RECOVERY OF STYRENE, MIXED XYLENE / TOLUENE

CLIENT INDIAN OIL CORPORATION LIMITED

PANIPAT

PREPARED BY ENGINEERS INDIA LIMITED

NEW DELHI

EIL JOB No.: A202

REPORT No. A202-RP-0241-0001 VOLUME 1 OF 1 AUGUST 2012

Copyright

This document is copyright protected by EIL and is produced for the client M/s IOCL. Neither this document nor any extract from it may be produced, stored or transmitted in any form for any purpose by any party without prior written permission from EIL. Request for additional copies or permission to reproduce any part of the document for any commercial purpose should be addressed as shown below: Ms. Jayati Ghosh DGM (PDD) Engineers India Limited 1, Bhikaiji Cama Place New Delhi-110066 India Telephone: 011-2676 3444 EIL reserves the right to initiate appropriate legal action against any unauthorized use of its Intellectual Property by any entity.

Template No. 5-0000-0001-T2 Rev. 1 Copyrights EIL – All rights reserved

Document No. A202-RP-0241-0001

Rev. No. 0

Page 1 of 96


RECOVERY OF STYRENE,

TOLUENE / MIXED XYLENES

Table of Contents 1.0 Executive Summary .......................................................................................................... 4

1.1 Background ..................................................................................................................... 4

1.2 Objectives of the Study ................................................................................................ 4 1.3 Design Basis ................................................................................................................... 4

1.4 Process Unit Facilities ................................................................................................... 5 1.5 Overall Material Balance .............................................................................................. 7 1.6 Utility Facilities ................................................................................................................ 8

1.7 Offsite Facilities .............................................................................................................. 8 1.8 Plot Plan Studies ............................................................................................................ 9

1.9 Capital Cost Estimates ................................................................................................ 10 2.0 Introduction ....................................................................................................................... 12

3.0 Scope ................................................................................................................................ 14

4.0 Design Basis .................................................................................................................... 16 4.1 Objective of the Study ................................................................................................. 16

4.2 Basis Of Study .............................................................................................................. 16

4.2.1 Design Case / Check Case .................................................................................. 16

4.2.2 Plant Capacity ......................................................................................................... 16 4.2.3 On-Stream Hours ................................................................................................... 17

4.2.4 Plant Over Design Margin ..................................................................................... 17 4.2.5 Plant Turn Down Capacity ................................................................................... 17

4.2.6 Feed Stock .............................................................................................................. 17

4.2.7 Products ................................................................................................................... 20

4.2.8 Recovery from the Two Units ............................................................................... 23

4.2.9 Feed, Product & Utility Prices .............................................................................. 23

4.2.10 Catalyst, Solvent & Chemicals Data ................................................................ 24

4.2.11 Flare Load ............................................................................................................. 25

4.3 Feed And Product Battery Limit Conditions ............................................................ 26 4.4 Client Obligations ......................................................................................................... 27

4.5 Exclusions ..................................................................................................................... 28 4.6 Client’s Special Requirement ..................................................................................... 28

4.7 Financial Parameters for Analysis............................................................................. 29 4.8 Utility specifications ..................................................................................................... 30

4.9 Product Dispatch Facility Summary .......................................................................... 32

4.10 Emission norms ........................................................................................................ 33 5.0 Project Location and Plot Plan Studies ........................................................................ 35

5.1 Project Location ........................................................................................................... 35 5.2 Plot Plan Studies .......................................................................................................... 35

5.2.1 Utilization of PX Area in Panipat Refinery ........................................................ 36

5.2.2 Utilization of PNCP Area ..................................................................................... 37

5.2.3 Conclusion ................................................................................................................. 44

6.0 Project Description .......................................................................................................... 47 6.1 Project Configuration ................................................................................................... 47

6.1.1 Unit Facilities ......................................................................................................... 47

6.1.2 Plant Capacity ....................................................................................................... 47

6.2 Overall Configuration for Various Options ............................................................... 48 6.3 Process Description..................................................................................................... 49

6.3.1 Styrene Recovery Unit ......................................................................................... 49 6.3.2 Toluene/Xylene Extraction Unit .......................................................................... 52

6.4 Material Balance .......................................................................................................... 56

6.4.1 Overall Material Balance ..................................................................................... 56



Rev. No. 0

Page 2 of 96




6.4.2 Styrene Recovery unit ........................................................................................ 58

6.4.3 Toluene-Xylene Extraction Unit......................................................................... 65 6.4.4 Hydrogen Saving in PGHU ................................................................................ 68

6.5 Utilities Description ...................................................................................................... 69 6.5.1 Utility Requirement ............................................................................................... 69

6.6 Offsites Description ..................................................................................................... 72 6.6.1 Flare System ......................................................................................................... 72

6.6.2 Offsite Facilities..................................................................................................... 72

6.6.3 OSBL Lines ........................................................................................................... 73 6.6.4 Fire Fighting Facilities .......................................................................................... 73

7.0 Environmental Considerations ...................................................................................... 75

7.1 Effluent Details ............................................................................................................ 75

7.1.1 Solid Effluents ....................................................................................................... 75 7.1.2 Liquid Effluents ..................................................................................................... 75

7.1.3 Gaseous effluent................................................................................................... 76

7.2 Flare Load ..................................................................................................................... 76 7.3 Effluent Treatment Plant ............................................................................................. 77

8.0 Project Implementation and Schedule ......................................................................... 79 9.0 Project Cost Estimates ................................................................................................... 83

9.1 Introduction ................................................................................................................... 83 9.2 Scope ............................................................................................................................. 83

9.3 Reference Document .................................................................................................. 83

9.4 Project Cost .................................................................................................................. 83

9.5 Key Assumptions ......................................................................................................... 84

9.6 Exclusions ..................................................................................................................... 84

9.7 Estimation Methodology ............................................................................................. 84

10.0 Annexure ....................................................................................................................... 96

Annexure-I Project Implementation and Schedule Annexure-II Estimated Project Cost for check cases Annexure-III Equipment List Annexure-IV Hook-ups Annexure-V Overall Block Flow Diagram Annexure-VI Schematic Process Flow Diagrams Annexure-VII Unit Layout Annexure-VIII Overall Plot Plan



Rev. No. 0

Page 3 of 96




Chapter 1.0 Executive Summary



Rev. No. 0

Page 4 of 96




1.0 Executive Summary

1.1 Background

The Panipat Naphtha Cracker Complex ( PNCP ) of Indian Oil Corporation Limited processes naphtha to produce ethylene and propylene streams for downstream polymer units and Pyrolysis gasoline ( Pygas) stream as by product. Presently capacity of the complex is 800 KTPA ethylene production with possibility to expand to 1000 KTPA ethylene production. The Butadiene Extraction unit ( BDEU) is under construction at PNCP. IOCL under a Joint Venture is also building a Styrene Butadiene Rubber ( SBR) plant at the same location. Presently only benzene is being recovered from the hydrogenated Pygas. But the Pygas stream from PNCP has a good potential of Styrene which in case recovered can be used as feed to the SBR unit. The C7+ stream after Benzene recovery also has potential for recovery of additional aromatics Toluene and mixed Xylene, which can be recovered for merchant sale or routed to the existing PX/ PTA complex. IOCL desires to check feasibility of either a Stand alone Styrene Recovery unit or an Integrated Styrene Toluene & Mixed Xylene Recovery within the existing Panipat Naphtha Cracker Complex (PNCP). The recovered Styrene is planned to be supplied on a dedicated basis to the SBR plant. The mixed Xylene product is planned to be fed to the existing ParaXylene complex and Toluene produced will be either routed to Refinery Gasoline pool or considered for merchant sales.

1.2 Objectives of the Study

The Objective of the study is to establish techno economic feasibility of producing Styrene, Toluene & Xylene considering maximum utilization of existing ISBL and OSBL facilities in PNCP using the available intermediate streams.

1.3 Design Basis

The following design and check cases have been considered for the study: Design Case: Naphtha Cracker capacity corresponding to 800 KTPA Option -1: Stand alone Styrene Recovery Unit Option -2: Integrated Styrene, Mixed Xylene and Toluene Recovery unit



Rev. No. 0

Page 5 of 96




Check case: Naphtha cracker capacity corresponding to 1000 KTPA Option-1: Stand alone Styrene Recovery Unit

Option-2: Integrated Styrene, Mixed Xylenes and Toluene Recovery configuration. Basis of Estimate:

The material balance, cost estimate, utility/ offsites data for design case has been estimated based on the Preliminary Technical Proposals provided by the Technology Licensor, GTC Technologies, LP Houston, USA, which corresponds to present design capacity of the PNCP complex. OSBL facilities have been envisaged by EIL based on the unit requirement.

For the check case, the following philosophy has been adopted:

a. Incremental Capital cost/ Operating cost for the existing NCU/ PGHU/ BEU facilities revamp corresponding to 1000 KTPA capacity have been excluded.

b. For the new Styrene/Toluene /Xylene recovery facilities suitable capacity factor has been used.

1.4 Process Unit Facilities

The three main Process units are the Feed Preparation unit, Styrene Recovery unit and Toluene and Xylene Recovery unit. a. Feed Preparation unit: This unit consists of two fractionating columns

(Deheptanizer & Deoctanizer) to fractionate Heavy Pyrolysis Gasoline Feed stream from the existing Naphtha Cracker to recover the C8 styrene concentrate heart cut .

b. Styrene Recovery Unit : The C8 heart-cut is selectively hydrogenated and styrene is recovered in the Extractive distillation column and drying section.

c. Toluene - Xylene Recovery unit : C7+ feed from existing Dehexanizer bottoms of Benzene Extraction Unit is fractionated to separate TX heart cut and then by extractive distillation method TX extract is recovered. The extract is further fractionated to produce high purity Toluene and mixed Xylene streams.



Rev. No. 0

Page 6 of 96




Unit Capacities

Capacities for the New units as part of the proposed configurations are as below:

Table 1.4.1: Unit Capacities

Sl.

No Capacity

Design Case

(KTPA)

Check Case

(KTPA)

1 Styrene Feed Preparation unit

(Basis: Feed to Styrene FPU) 356 445

2 Styrene Recovery unit

(Basis: Styrene Product yield)

17

( 20 note:1)

21

( 25 note: 1)

3 Toluene / Xylene Recovery unit

(Basis: C7 feed ) ( option -2 only ) 220 275

Note:

1. The Styrene Recovery unit capital cost has been worked out based on design capacity in parenthesis, (~ 6 % wt Styrene potential in feed) based on Licensor’s feedback . However for material balance and operating expenditure Naphtha Cracker estimated yield ( 5.1% wt styrene potential ) has been considered. 2. The feed to existing Pyrolysis Gasoline Hydrogenation Unit (PGHU) will be reduced to the extent of recovered Styrene.



Rev. No. 0

Page 7 of 96




1.5 Overall Material Balance

The estimated overall material balance for Standalone Styrene recovery and integrated Styrene and Toluene/ Mixed Xylene recovery is given below :

Table 1.5.1: Overall Material Balance

Sl. No.

Feed Streams / Product Streams

Design Case Option-1 (MTPA)


Check Case Option-1 (MTPA)


Feed Streams

1 HPG 356046 356046 445058 445058

2 C7 feed to TX

220400

275500

3 Hydrogen 38 38 48 48

4 Chemicals 60 60 75 75

5 Flux oil 269 269 336 336

Total 356413 576813 445516 721016

Product Streams

5 Offgas 38 38 48 48

6 Styrene 16532 16532 20665 20665

7 Toluene 0 111000 0 138750

8 Mixed Xylene 0 61700 0 77125

9 C9+ Streams from SRU 75578 75578 94473 94473

10 C7-C8 Raffinate from FPU / SRU

262234 262234 327793 327793

11 Heavies/ Residues from SRU

2031 2031 2539 2539

12 C7-C8 Raffinate from TX 0 41100 0 51375

13 C9+ heavies + T drag from T/X

0 6600 0 8250

Total 356413 576813 445516 721016



Rev. No. 0

Page 8 of 96




1.6 Utility Facilities

The utility requirement for the new units and OSBL facilities is given below.

Table 1.6.1: Utility Requirement

Sl. No.

Utility Design Case

Option-1

Design Case

Option-2

Check Case Option-1

Check Case Option-2

1 HP Steam, Tons/hr 0.0 7.1 0.0 8.9

2 IP Steam, Tons/hr 23.6 61.5 29.5 76.9

3 LP Steam, Tons/hr 9.9 9.9 12.4 12.4

4 Cooling Water, m3/hr 785 883 981 1103

5 Chilled Water, m3/hr 7.2 7.2 9.1 9.1

6 Power, KWH 365 745 458 931

7 BFW, m3/hr 0.6 0.6 0.7 0.7

8 Nitrogen, Nm3/hr 57 253 57 253

9 Instrument Air, Mn3/hr 311 541 311 541

The utilities required for the new units are to be availed from the existing Utility systems of the PNCP complex where the units have been planned. Suitable tapping from the existing headers will be taken. The existing cracker warm flare as well as ETP will also be utilized.

1.7 Offsite Facilities

The additional Offsite facilities envisaged are :

Table 1.7.1: Offsite Product Storage Capacity

S. No. Service No. of Tanks Capacity per tank

1 Styrene 1 700 m3

2 Toluene 2 2800 m3

3 Mixed Xylene 2 2300 m3

In addition to the tanks, suitable pumping facilities for all the products and loading facilities for Toluene is also envisaged. OSBL lines shall be provided to route the feed & product streams to and fro units and Offsite area including Toluene and mixed Xylene to PX/PTA area.



Rev. No. 0

Page 9 of 96




1.8 Plot Plan Studies

A detailed study of the existing Plot plans of both the PNCP complex and the PX/PTA units in the Refinery were carried out as part of the Plot Plan studies. Ten separate locations as identified by IOCL were all studied , keeping in view to meet all statutory norms, OISD guidelines, existing Pipe Rack locations, necessary space requirements for approach , Crane movements, minimum utilization of Greenfield area and other strategic advantages. Locating all new facilities in the cracker battery limit and PNCP area was found advantageous due to better construction management, coordination and safety, utilization of common Construction area , utilization of common Utility systems, hook-ups and effective interphasing. The plot plan study in the existing NCU area has been carried out with following objectives.

To accommodate FPU (Feed preparation unit) in available Brownfield area

To accommodate Styrene Recovery Unit in available Brownfield area

To accommodate TX recovery unit in available Brownfield area

Detailed study with available and identified Brownfield areas revealed that locating all facilities in one particular location has following advantages.

Safe and easy constriction

Common Pipe rack

Compact Design

Minimum no. of hookups However considering IOCL’s requirement of maximum utilization of Brownfield area the following areas have been identified-

FPU & PA (phenyl-acetylene ) Selective hydrogenation reactor & associated equipments- Area 41 m x 19.5 m near space at the west side of T2401 and south of sub station #2

Balance Styrene recovery unit equipments- Area 48 m x 50 m near space near to the Methanol tank 11-T-7703 and on the north of Butadiene extraction unit

TX recovery unit equipments Coordinates -Area 136 m x 39 m near PGHU

Offsite facilities (as defined in para 1.7)- Area 130 m x 115 m near construction / fabrication area EPCC-1



Rev. No. 0

Page 10 of 96




1.9 Capital Cost Estimates

The total Capital cost for all the Process Units including Utilities and Offsite facilities for the Design case options is indicated as follows.

Table 1.9.1: Project Cost

The check case options consider higher capacities of the units. The estimated project cost for this case are:

Table 1.9.2: Project Cost (Check Case)

Sl. No.

Project Cost

Foreign Component

(Fc, ` Crore)

Indian Component

(Ic, ` Crore)

Total

(` Crore)

1 Design Case Option-1 50.84 139.72 190.56

2 Design Case Option-2 82.67 246.39 329.06

Sl. No.

Project Cost

Foreign Component

(Fc, ` Crore)

Indian Component

(Ic, ` Crore)

Total

(` Crore)

1 Check Case Option-1 58.13 159.04 217.17

2 Check Case Option-2 94.51 281.0 375.51



Rev. No. 0

Page 11 of 96




Chapter 2.0 Introduction



Rev. No. 0

Page 12 of 96




2.0 Introduction IOCL is planning to setup a Stand alone Styrene Recovery unit or alternatively an

Integrated Styrene Recovery along with Mixed Xylene/ Toluene Recovery unit from Heavy Pyrolysis Gasoline in the existing of Naphtha Cracker unit at Panipat. Heavy Pyrolysis Gasoline is available from Panipat Naphtha Cracker which is a potential feedstock for production of high purity Styrene. Mixed Xylenes and Toluene can be sourced from the C7+ stream after Benzene recovery .

Currently a 120 KTA capacity of Styrene Butadiene Rubber (SBR) project is under

construction phase at Panipat in Joint venture . The SBR unit uses Butadiene from Panipat Naphtha Cracker as major feed stock along with about 25 KTA of Styrene.

The recovered Styrene can be supplied on a dedicated basis to the SBR unit and mixed

Xylenes will be fed to the existing ParaXylene (PX) unit at the Panipat Complex. Toluene produced will be routed to the extent possible to the PX plant while balance will be considered for merchant sales.

The Preliminary Technical Proposals provided by the Technology Licensor GTC

Technologies, LP Houston, USA has been used as base data. Further optimization in the scheme has been done by EIL in utilizing existing hardware.

The study has been carried out corresponding to 800 KTPA capacity of NCU and future

capacity of 1000 KTPA of NCU as a check case. Impact of this augmented capacity in the check case for the existing NCU, PGHU, BDEU and BEU units are out of scope of this study.



Rev. No. 0

Page 13 of 96




Chapter 3.0 SCOPE



Rev. No. 0

Page 14 of 96




3.0 Scope The feasibility study has been carried out corresponding to 800 KTPA capacity of NCU

and future capacity of 1000 KTPA of NCU as a check case for following two cases. Case 1: Stand alone Styrene recovery and styrene supply to nearby SBR JV project of IOC. Case 2: Integrated Styrene, Mixed Xylene and Toluene recovery configuration Impact of this augmented capacity in the check case for the existing NCU, PGHU, BDEU

and BEU units are out of scope of this study. The base data for this study is the Preliminary Technical Proposals provided by the

Technology Licensor GTC Technologies, LP Houston, USA with further optimization in the scheme by EIL in utilizing existing hardware’s.

The feasibility report addresses following facts -

Evaluation and estimation of project cost for alternate options

Identifying suitable integration needs for feed, products, intermediate products and utilities

Optimization of space use and identifying proper space for new facilities

Product Quality, material balance, utility consumption details along with Effluent generation, treatment and disposal information of effluent

Project Implementation schedule & bar chart



Rev. No. 0

Page 15 of 96




Chapter 4.0 Design Basis



Rev. No. 0

Page 16 of 96




4.0 Design Basis

4.1 Objective of the Study

The major objectives of the feasibility study are :

Produce Styrene for captive use

Produce Toluene and Xylene for captive use and alternatively for merchant sale

Produce mixed Xylenes for captive use

Minimize Capex considering maximum utilization of existing ISBL facility based on

Licensor’s input

Estimate offsite & utility requirement for new facility and retrofit with existing system

to maximum extent

Finalize location of the proposed facilities with suitable tie in

Maximize synergy in refinery and petrochemical complex

4.2 Basis Of Study

4.2.1 Design Case / Check Case

Design Case: Naphtha Cracker capacity corresponding to 800 KTPA

Option -1: Stand alone Styrene recovery Option -2: Integrated Styrene, Mixed Xylene and Toluene recovery configuration. Check case: Naphtha cracker capacity corresponding to 1000 KTPA Option-1: Stand alone Styrene recovery Option-2: Integrated Styrene, Mixed Xylene and Toluene recovery configuration

4.2.2 Plant Capacity

Capacity of each unit for the Design Case & Check Case are as follows :

Table 4.2.2.1: Plant Capacity

Sl.

No Capacity

Design Case

(KTPA)

Check Case

(KTPA)

1 Styrene Feed Preparation unit

(Feed to Styrene FPU) 356 445

2 Styrene Recovery unit (Styrene 17 21



Rev. No. 0

Page 17 of 96




Product)

3 Toluene / Xylene Recovery unit (C7

feed ) applicable for option -2 220 275

Note

1 All capacity numbers are rounded off. 2. The Styrene recovery capacity indicated are based on 5.1 % wt Styrene

potential in feed, which will be the basis for the Feasibility Study for estimating Material Balance, and OPEX, while 6 % wt styrene recovery is considered for CAPEX estimation. Which work out as 20 KTPA & 25 KTPA for design and check cases respectively.

4.2.3 On-Stream Hours

On-stream time of 8000 hours/year will be considered.

4.2.4 Plant Over Design Margin

The overdesign capacity for equipment shall be same as considered by Licensor for ISBL facility. Same shall be used for cost estimate of new facility.

For the Styrene Recovery plant hardware design, 6% Styrene potential will be considered in feed to allow additional contingency. However material balance will consider 5.1 % wt styrene in line with NCU.

For Toluene-Xylene recovery unit facility, Toluene –Xylene feed will be considered based on 5.1% styrene potential which will provide some overdesign margin on capacity.

For utility and offsite facility standard over design margin as per EIL’s practice will be followed considering Licensor’s data as basis.

4.2.5 Plant Turn Down Capacity

The turndown capacity for each of the facilities are as follow-

Table 4.2.5.1: Plant Turn Down Capacity

Sr no Unit Turn down capacity

1. Styrene recovery 60%

2. Xylene Recovery 50%

3. Toluene recovery 50%

4.2.6 Feed Stock



Rev. No. 0

Page 18 of 96




Feed stock for the new facility i.e. Styrene recovery unit for option-1 & 2 and feed to Toluene/Xylene recovery facility for option-2 are indicated below.

4.2.6.1 Feed Stock for Styrene Recovery Unit

Table 4.2.6.1.1: Feed for Styrene Recovery Unit

Composition (wt %) (Gasoline Stripper Bottoms)

6.0 Wt% Styrene case

5.1 Wt% Styrene case

H2 0.000 0.000

CO 0.000 0.000

CO2 0.000 0.000

H2S 0.000 0.000

CH4 0.000 0.000

Acetylene 0.000 0.000

Ethylene 0.000 0.000

Ethane 0.000 0.000

Propadiene/Methylact 0.000 0.000

Propylene 0.000 0.000

Propane 0.000 0.000

Butadiene/C4 Acetylen 0.097 0.098

Butylenes 0.009 0.009

Butanes 0.004 0.004

C5 HCs 1.882 1.901

C6 Non Aromatics 5.473 5.527



Benzene 12.566 12.691

Toluene 26.274 26.535

Xylene/Ethylbenzene 17.006 17.175

Styrene 6.000 5.066

C9-204 oC 21.018 21.227

204-288 oC - PGO 0.011 0.011

288+ oC - PFO 0.001 0.001

Notes:

1. 6.0 wt% Styrene Case is as per Licensor’s input refer Licensor Technical proposal

corresponding to 800 KTPA NCU capacity. This is used for equipments/ hardware

specification for the Styrene FPU and Styrene Recovery unit.

2. 5.1 wt% styrene case is as per 800 KTPA NCU material balance provided by M/s

Lummus. This used for material balance for Styrene recovery and all down stream

facilities.



Rev. No. 0

Page 19 of 96




4.2.6.2 Feed Stock for Toluene/Xylene Recovery Unit

The composition of the feedstock as provided by IOCL from existing Dehexanizer bottoms which is based on full range Pygas hydrotreating without Styrene recovery is as presented below.

Table 4.2.6.2.1: Dehexanizer Bottom Without Styrene Recovery

Components Wt%

Cyclohexane 0.02

Benzene 0.06

C7 Paraffins 7.38

1,1 dimethyl cyclo C5 0.05

cis 1,3-dimethyl cyclo C5 0.34

trans 1,3-dimethyl cyclo C5 0.34

cis 1,2-dimethyl cyclo C5 0.24

trans 1,2-dimethyl cyclo C5 0.62

Methyl cyclohexane 2.22

Ethyl cyclopentane 1.29

Toluene 46.79

C8 Paraffins 3.32

Total dimethyl cyclohexane 0.66

Ethyl cyclohexane 0.07

n-propyl cyclopentane 0.20

Isopropyl cyclopentane 0.13

Total trimethyl cyclopentane 1.15

Ethylbenzene 13.30

Xylenes 19.79

C9 plus 2.03

Total 100

Related Specs

Bromine Index, mg/100g) 10 (max

Total Sulfur, wt ppm 0.2 (max)

Estimated RON 100

Estimated MON 94

Density 844 kg/m3 at 15.5°C

Benzene Content 0.054 to max 0.9 vol%

Aromatics 82 wt%

Olefins 60 wt ppm max

After installation of styrene recovery unit, the composition of the feedstock to

Toluene/Xylene would be changed due to removal of styrene from feed to the pygas hydrotreating unit. The estimated feed composition for the two styrene recovery unit cases are as presented below:



Rev. No. 0

Page 20 of 96




Table 4.2.6.2.2: Estimated Feed Composition for Toluene/Xylene Recovery Unit

Components

5.1 wt % Styrene case wt%

6 wt% Styrene case wt%

C6 Naphthenes 0.02 0.02

Benzene 0.06 0.06

C7 Paraffins 7.78 7.92


Toluene 51.27 51.13

C8 Paraffins 3.57 3.63


Ethylbenzene 6.85 5.26

p-Xylene 4.46 4.54

m-Xylene 12.12 12.33

o-Xylene 4.68 4.76

C9+ non-aromatics 0.11 0.11

C9+ aromatics 2.08 2.11

Total 100 100

Notes: Basis: As per Licensor proposal dated August 2010 5.1 wt% Styrene in feed will be the basis for the Feasibility Study for Toluene-Xylene recovery unit.

4.2.6.3 Hydrogen

Hydrogen also will be required for selective hydrogenation of the Styrene recovery unit feed to convert Phenylacetylene to Styrene. The quality of H2 feed stock available based on the Panipat Naphtha Cracker is as given below :

Table 4.2.6.3.1: Hydrogen Composition

Component

Hydrogen 95.68 mol%

Methane 4.32 mol%

Carbon monoxide 1 mol ppm

CO2 + Nitrogen Traces

Chloride content 1 vol ppm

4.2.7 Products

The major products from the new facilities are :

a. Styrene for option-1 b. Styrene, Toluene, Mixed Xylenes for option-2



Rev. No. 0

Page 21 of 96




4.2.7.1 Product Rate

Table 4.2.7.1.1: Product Rate

Product Name Production Rate

@ 5.1 % Styrene Case (Wt %)

KTPA Kg/hr

Styrene 16.5 2066.7

Toluene 111 13877

Mixed Xylenes 61.7 7713

Note: Hydrogenated Pygas product yield will be reduced with Styrene Recovery.

4.2.7.2 Product Specifications:

The quality of product will be as follows:

A. Styrene

Table 4.2.7.2.1: Styrene Product Specification

Property Specified Value

Purity, WT% 99.5% Min

Water Content 180 wppm Max.

Aldehydes (as Benzaldhyde) 0.02 wt% Max.

Peroxides (as Hydrogen Peroxide) 0.010 wt% Max.

Sulfur (as S) 0.003 wt% Max.

Chlorines (as Chloride) 0.01 wt% Max.

Polymer Content 0.002 wt% Max.

Solubility of Polymer Complete in Benzene

Viscosity@ 25oC 0.87 cps Max.

P-Tertiary Butyl Catechol 10-30 wppm

Color 10 Max.

Appearance Clear

The above specification is in line with the Panipat SBR unit Feed.

b. Toluene

Table 4.2.7.2.2: Toluene Product Specification

Property Specified Value Test Method

Purity, wt. % 99.7 min ASTM D-2360

Non-Aromatics, wt.% 0.2 max ASTM D-2360

Benzene, wt. % 0.05 max ASTM D-4492

Aromatics C8,wt.% 0.05 max. ASTM D-2360



Rev. No. 0

Page 22 of 96




Acid Wash Color 2 ASTM D-848

Appearance Clear Liquid, Free of

Sediment or Haze

Visual

Color, APHA 20 ASTM D-1209

Specific Gravity,

15.56/15.56 oC

0.865 ~ 0.868 ASTM D-891

Sulfur content, wppm 2.0 max. ASTM D-4045

c. Mixed Xylenes

Table 4.2.7.2.3: Mixed Xylene Product Specification

Property Specified Value Test Method

Purity, wt. % 99.0 min ASTM D-2360

Non-Aromatics, wt. % 0.8 max ASTM D-2360

C9+ Aromatics, wt. ppm 610 max ASTM D-2360

Total distillation range, oC 10 max. ASTM D-850

Initial distillation range, oC 135 min. ASTM D-850

Dry point, oC 145 min. ASTM D-850

Acid Wash Color 5 max. ASTM D-848

Color, APHA, max. 20 ASTM D-1209

Specific Gravity, 15.56/15.56 oC 0.860 ~ 0.870 ASTM D-891

Sulfur content, wppm 3.0 max.

(Note-2)

ASTMD-4045

As per PX/PTA Licensor specification the limits on following impurities need to be ensured for the mixed Xylene specification. IOCL to obtain confirmation on the specifications as a PX/PTA feed after interaction with PX/PTA Licensor.

Table 4.2.7.2.4: Mixed Xylene Product Impurities Specification

S NO Component Specification

1 BZ 500 wt ppm Max.

2 MEB 100 wt ppm Max.

3 Other C9A 500 wt ppm Max.

4 C10A+ 10 wt ppm Max.

5 Total Sulphur 1 wt ppm Max.

6 Total Nitrogen 1 wt ppm Max.

7 Water 60 wt ppm Max.

8 Organic Chloride 3 wt ppm Max.

9 BI(mg/100gm) 20 Max.

10 Active Oxygen 1 wt ppm Max.

11 Carbonyl No 2 wt ppm Max.

12 Dissolved Oxygen 1 wt ppm Max.

13 Total Chloride 5 wt ppm Max.

14 Lead 5 wt ppm Max.

15 Arsenic 1 wt ppm Max.

16 Copper 1 wt ppm Max.

17 Colour (Pt-Co scale) 10 Max.



Rev. No. 0

Page 23 of 96




Notes:

1. This mixed xylene will be as available from the Xylene column of Xylene Recovery

unit. The mixed xylene stream will be routed through the Parex and Isomerization

unit in the existing PX/PTA unit. Adequacy of existing unit for this stream is out of

scope of this study.

2. IOCL desired the product quality to meet 1ppm sulfur specification as per PX/PTA

Licensor. This needs to be done by PGHU by changing PGHU operation suitably

which is excluded from this study scope. However Licensor estimates that the

present operation of PGHU may be adequate to meet this specification. This issue

needs to be advised by IOCL.

3. Licensor has not informed about impurities such as Benzene, Nitrogen, Water ,

Total organic chloride, BI, Oxygen(active and dissolved), carbonyl no, Lead, Arsenic,

Copper in the product. However Licensor has confirmed that during design all the

requirement of feed to PX/PTA will be taken care suitably.

4.2.8 Recovery from the Two Units

The overall recovery for styrene and Toluene / Xylene are 94.9 % wt and 99.95 % wt.

4.2.9 Feed, Product & Utility Prices

(a) Feed and Product Unit Rates

Table 4.2.8.1: Feed and Product Unit Rates

S.No. Feed/ Product Rs. / MT

1. Heavy Pyrolysis gasoline 41779

2. Hydrogen 116892

3. Hydrogenated C7+ 41779

4. Styrene 60649

5. Toluene 48358

6. Mixed Xylenes 43419

9. C7 - C8, Raffinate 38964

10. C9+ 38803

12. Off gas 30548

13. Heavies residues 38803

Note: As per IOCL, the feed price to Styrene Recovery unit is to be considered same as RPG & feed to the Toluene/Xylene Recovery unit will be same as HPG.



Rev. No. 0

Page 24 of 96




(b) Utility unit rates

Table 4.2.8.2: Utilities Unit Rates

As the financial analysis in out of scope EIL’s work, hence this data is only for information.

4.2.10 Catalyst, Solvent & Chemicals Data

Styrene: Recovery Unit –

Table 4.2.9.1: Catalyst, Solvent & Chemicals Data

S.No. Name Unit Initial

charge

Unit Price ($/kg) Estimated Annual

Consumption and

life

1.

PA Selective

Hydrogenation Catalyst

M3 7 121.72

(Catalyst +

precious Metal)

5 years life, with 3-4

regenerations

2. Techtiv-200 Ton 90 8 0.65/year

3. True Inhibitor GE S310 Ton 0.0225

4.5/year

4. C8 Inhibitor GE 20Y3 Ton 0.9 23.6/year

5. Mono-ethanolamine (MEA Ton 0.15 7.2/year

6. Antifoaming agent Ton - 0.48/year

7. Non Sulfur Inhibitor (DNBP) Ton - 0.035-0.05 /year*

8. TBC Inhibitor Ton - 1 -2 /year

9. GT-A200 Chemical

Treatment Additive Ton 12 4.6 60/year

S.No. UTILITY UNIT Rs. / Unit

1. Power KWh 7.96

2. HP Steam Ton 1494.63

3. MP Steam Ton 1494.63

4. LP Steam Ton 1494.63

5. Cooling water m3 0.46

6. Nitrogen/ Compressed air Nm3 0.51

7. BFW water M3 23.15



Rev. No. 0

Page 25 of 96




Toluene/ Xylene Recovery Unit :-

Table 4.2.9.2: Catalyst, Solvent & Chemicals Data

S.No. Name Unit Initial

charge

Unit Price

($/kg)

Estimated Annual

Consumption and

life

1. Techtiv-500 M3 180 T $9.00 /kg 0.22 t/year

2. Antifoaming agent Ton 390-450 kg/h

5. Monoethanolamine

(MEA)

Ton 320 l/year

4.2.11 Flare Load

No flare load data is available however, considering the present flare capacity being extremely high it has been decided to consider the flare will be connected to NCU hot flare. The new units being extractive distillation units, no major loads are expected for cumulative failure cases (general power failure or cooling water failure).



Rev. No. 0

Page 26 of 96




4.3 Feed And Product Battery Limit Conditions

Table 4.3.1: Solid Feed And Product Battery Limit Conditions

Stream name

Op.

pressure

(kg/cm2g)

Op. Temp

(deg C) Source /Destination

FEEDS

Heavy Pyrolysis

gasoline

4.4 121 Gasoline stripper bottoms

Hydrogen 29.2 19 From H2 header in PNCP

Hydrogenated C7+ 4.0 40 From Benzene Extraction Unit

PRODUCTS

Styrene 4.0 15 To Styrene tank (new)/SBR unit processing

Toluene 4.0 40 To Toluene tank/ PX unit/ Merchant Sale

Mixed Xylenes 4.0 40 To Xylene tank/PX unit(Note-1)

C7-C8 Raffinate 4.0 40 To be recycled as feed to NCU/ to HPG

storage

Toluene drag 4.0 40 To be routed to HSD Pool

C9+ heavies 4.0 40 To be routed to HSD Pool

Note:

1. It is considered that the Toluene – Xylene Extraction unit will not include splitter.



Rev. No. 0

Page 27 of 96




4.4 Client Obligations

4.4.1 Client To Provide/Confirm

i. All appropriate existing facility for Refinery/Petrochemical complex for estimating new requirement

ii. Feed, Products, catalyst, chemical and utility prices

iii. Input on probable locations of new facilities

iv. Confirm the availability of augmented utility requirement for new facility in the existing utility system.

v. Existing plot plan for utility and offsite facilities

vi. Input for Licensor Royalty/know how charges, and BDEP and Detail engineering

cost.

4.4.2 Licensor To Provide/Confirm

i. PFD and stream summary for Feed preparation/ Styrene recovery units with different styrene content (5.1 & 6%) corresponding to 800 KTPA case. Refer annexure- IV for Licensor report for 5.1 wt% and 6 wt% styrene potential in feed.

ii. PFD/Stream summary for Toluene /Xylene recovery units with different styrene content in feed corresponding to 800 KTPA.

iii. Check case 1000 KTPA will be based on proration factor on 800 KTPA operation.

iv. Chemical and catalyst requirement and cost for first charge / annual operating cost.

v. Solvent type, cost for first charge / annual operating

vi. ISBL equipment details for further engineering and costing

a. Details of columns, internals, heaters, exchangers, pumps, compressors, special equipments with all necessary information good for further costing.

b. List of proprietary equipment, with acceptable vendor names, if any. The delivery period of such proprietary equipment is also to be indicated. Cost of proprietary item also to be indicated.

c. Preliminary estimate of the total installed cost of the unit, (excluding catalyst, additives, chemicals and proprietary supplies) on US Gulf Coast basis.



Rev. No. 0

Page 28 of 96




4.5 Exclusions

Change in product yield and economy change in total PNCP complex due to incorporation of new facility.

Estimates of higher Reactor life for PGHU, due to styrene recovery

Change in feed and products of BEU due to introduction of new units will be nominal ; hence no effect on BEU feed and product will be considered.

There will be a small reduction/implication in utility consumption in existing facility of PGHU due to change of scheme. Hence any impact on utility consumption of PGHU will not be considered.

Check of PX/PTA unit facility for additional MX/Toluene

Check of PGHU to meet sulfur specification in MX

Any check of existing units utilities to achieve 1000 KTPA cracker capacity (corresponding check case) for existing units

Financial analysis

4.6 Client’s Special Requirement

i. Facilities for Styrene recovery including feed preparation and treating to be

considered within cracker unit B/L preferably in the identified Brownfield areas.

ii. Toluene/Xylene recovery unit facilities will be located suitably in NCU Brownfield /PX/PTA area.

iii. No feed storage will be envisaged for styrene recovery Unit. In case Styrene recovery unit is down, the RPG can continue being routed to PGHU as is being done currently. In case of PGHU shut down, Heavy gasoline will be routed through the Styrene recovery and the light gasoline + C7- stream+ Styrene raffinate + C9+ will be routed to the existing RPG tank .

iv. SBR project is in JV and none of its tankage will be considered .New tankage for 7 days storage (as per Licensor recommendation) shall be considered for Styrene.

v. Based on Licensor input no off-spec products storage will be required. In case of off spec generation, there will be provision in offsite to send back the material to RPG storage.

vi. Mixed xylene and Toluene extraction new storage and dispatch facility to be considered in the study. Also feasibility of utilising loading and unloading facility in existing need to be studied as per IOCL input.

vii. No new facility for DCS and MCR need to consider.

viii. No new facility required for infrastructure /township .



Rev. No. 0

Page 29 of 96




4.7 Financial Parameters for Analysis

Table 3.7.1: Financial Parameters for Analysis

S.No Parameter Value

1 Construction Period 36 month

2 Project Life 15 years

3 Debt/Equity Ratio 60:40

4 Expenditure pattern Concurrent spending of equity and debt

5 Loan Repayment period 8 years

6 Moratorium period 2 years

7 Interest on long term debt 11.8%

8 Capital Phasing (Total Period)

1 Year In house data




9 Capacity Build-up

1st Year 60%

2nd

Year 80%

3rd

Year 100%

10 Corporate Tax Rate 32.45%

11 MAT 20.01%

Note: As financial analysis is excluded from the scope of EIL’s project, the above data are only for information.



Rev. No. 0

Page 30 of 96




4.8 Utility specifications

Utility specifications are provided on the following pages. With the exception of steam and fuel gas, which are generated ISBL, all other utilities are imported from the central utility center.

4.8.1 Steam

The following table summarizes the steam header conditions and steam conditions for

the equipment design.

Table 4.7.1.1: Steam Header Conditions steam Conditions for Equipment Design

Genera

tion

Steam Header Conditions

Header Conditions

for Equipment Design (1)

Steam Conditions for Equipment Specification

Mechan

ica

l D

esig

n

At Turbine Inlet

At Turbine Extraction

At Heat Exchanger Inlet

Min Nor. Max

Medium Pressure (MP)

Pressure, kg//cm2g 15.1 16.3 17.7 15.1 14.1 15.6 13.6 20.4/FV

Temperature, °C 270 285 310 270 265

265 350

Low Pressure (LP)

Pressure, kg//cm2g 3.6 4 4.5 3.6

4.1 2.7 6.5/FV

Temperature, °C 195 200 225 195

190 288

Low Pressure Desuperheated (LPS)

Pressure, kg//cm2g

2.7 6.5/FV

Temperature, °C

148.2 288

Notes: 1. Minimum steam header conditions are used for design of equipment (exchangers and turbines) with suitable pressure drops in lines to the users.

4.8.2 Cooling Water

Normal Design

Supply Pressure, kg/cm2g 5 10

Supply Temperature, °C 33.0 max. 65

Return Pressure, kg/cm2g 2.2

Return Temperature, °C 45 max.

Note: 1. Design fouling factor for cooling water: 0.0004 h-m2-°C/kcal 2. Cleanliness factor for surface condenser: 0.80



Rev. No. 0

Page 31 of 96




4.8.3 Instrument Air

Quality: oil and dust free Dew point: -40°C at atmospheric pressure Conditions

Normal Mechanical

Design

Pressure, kg/cm2g 7.0 6.5(min)

10

Temperature, °C 40 65

4.8.4 Plant Air

Quality :oil and dust free Conditions

Normal Mechanical Design

Pressure, kg/cm2g 6.0 (min) 10


4.8.5 Nitrogen

Quality:

Parameter Unit Specification

Purity vol% (min) 99.99

Oxygen vol ppm 3

Carbon dioxide vol ppm 3

Carbon monoxide vol ppm Traces

Oil Nil

Dew Point °C at atm. pressure (-) 100°C

Conditions

Normal Mechanical Design

Pressure, kg/cm2g 6.0 (min) 10.5


4.8.6 Electricity

Power for electric drives and lighting shall be: 1. 6600V ± 6%, 3 phase, 50 Hz ± 3% resistance grounded for drives of 160 kW. 2. 415V ± 10%, 3 phase, 50 Hz ± 3% for drives up to 160 kW, neutral is solidly earthed. 3. For instruments and lighting the voltage shall be 240V ± 6%, 50 Hz ± 3%, single phase AC grounded. 4. UPS system shall be 110V AC.



Rev. No. 0

Page 32 of 96




4.8.7 Fuel Gas

Fuel gas is expected to be used for blanketing / Flare header purging which will be utilizing existing facility.

4.9 Product Dispatch Facility Summary

Table 4.9.1: Product Dispatch Facility Summary

S. No.

Stream

Flow rate in

KTPA

Pumps in offsite area

Remarks For storage

No

s.

Capacity (Suggested)

1. Heavy PyGas

356 Nil Considering no routing through offsite

No storage to be considered for heavy PyGasoline to Styrene feed preparation

2. C8 heart cut (Styrene recovery unit Feed)

84.5/ 89.1 (Note-1)

Nil Considering no routing through offsite

No storage for feed to Styrene recovery will be considered

3. Hydrogenated C7+ cut (To T/X unit )

Nil/239

1+ 1 50% of flow (Considering usual routing from unit to unit) Only flexibility through tankage during one unit shutdown

5 days storage will be considered . (Existing HPG storage will be used)

4. Styrene 16.5/ 20.3 (Note-1)

1 + 1

50% of flow(Considering normal routing from Styrene to SBR) Only flexibility through tankage during one unit shutdown

7 days storage will be considered

5. Toluene 1 + 1

100% of flow corresponding to loading facility

10 days storage will be considered (Note-2)

6. Mixed Xylenes

1 + 1

50% of flow(Considering normal routing from Xylene recovery to PX unit) Only flexibility through tankage during one unit shutdown

15 days storage will be considered

Note-:1 Based on Styrene recovery potential i.e. 5.1% wt Styrene & 6% wt Styrene in feed. Note-2 Following destination will be considered for Toluene product-

(i) Merchant sell (ii) Tatoray unit (iii) Blending in gasoline pool

Table 4.9.2: Product Dispatch Facility Summary

S. No.

Product Source Remarks/mode of dispatch

1. Hydrogenated Pyrolysis

Pyrolysis Gasoline Hydrogenation Unit (PGHU)

As existing



Rev. No. 0

Page 33 of 96




Gasoline(HPG)

2. Styrene Styrene recovery unit Only captive use, No facility for export

3. Toluene Toluene/Xylene recovery unit

Captive use/Road tanker for export

4. Mixed Xylenes Toluene/Xylene recovery unit

Only captive use in Existing Facility

Note-1: IOCL to indicate whether any existing facility is available for reutilization.

4.10 Emission norms

There is no additional flue gas generation or SOX generation expected due to the new units. Hence emission norms will be as per existing.



Rev. No. 0

Page 34 of 96




Chapter 5.0 Project Location and Plot Plan Studies



Rev. No. 0

Page 35 of 96




5.0 Project Location and Plot Plan Studies

5.1 Project Location

Details of plant location are as given below. Site Location Distance - Plant Location : Baljatan Village - State : Haryana - Nearest Important Town : Panipat 20 Kms - Nearest Railway : Panipat 20 Kms - Nearest Port : - - Nearest Airport : Delhi 100 Kms - Nearest National Highway : NH-1 Source of Water : - Munak Headworks - Recycled Treated Effluent Water Rainy season(Mansoon) : June to September Annual Rainfall : 72 mm (for 1 hr period) 218 mm (for 24 hr period)

5.2 Plot Plan Studies

As part of FR location of the new Styrene recovery and Toluene / Xylene recovery facilities have been studied in the existing PNCP complex and alternatively PX/ PTA units of Panipat Refinery. The major thrust has been provided on

Lowering the CAPEX/OPEX.

Constructability issue

Optimum utilization of Brownfield area

Vacant Spaces within the existing NCU and associated areas and the existing PX/ PTA units in the Refinery area were identified by IOCL to study the possibility of accommodating the new facilities required. IOCL desired that use of vacant space (i.e. 110m x 220m) available in NCU should be minimized in view of the additional new projects envisaged as part of their expansion plans. Studies have been carried out based on information available on as built PNCP plot plan superimposing the under construction Butadiene facility and also as built PX/PTA area layout provided by IOCL. A site visit was also carried out to find and deliberate possible pros and cons and physically examine the area availability and alternate options. Following basis have been adopted for the plot plan study.

New feed preparation unit and Styrene recovery unit to be considered within the

PNCP (NCU area) as the feed preparation, Styrene recovery unit are totally

integrated with existing NCU and PGHU.

For placing of new TX recovery unit, either vacant area in NCU or PX/PTA can

be studied as operationally TX recovery unit can be considered part of any of the

two complexes.



Rev. No. 0

Page 36 of 96




5.2.1 Utilization of PX Area in Panipat Refinery

The areas identified as part of the Plot plan studies are the vacant spaces available in

Locations A, B & C which can be utilized for TX unit are indicated below:

Location A: on the west side of NHT/ CCR up to the B/L on the west area. The

identified area was found to be inadequate.

Location B: Plot area between PX1 and PX2. It was highlighted that this area is

surrounded by Equipments, with no required approach so there will be bottleneck in

constructability for construction & maintenance. The area available is also found to be

inadequate and thus not considered.

Location C: The PX2 area near the Heater, Major constraints in the area are two tower

monitors from Underground fire water lines which will be eminent blockage for Crane

Access and thus constructability.

Based on the above, the identified locations in the PX/PTA area were found to be not

useful for the new TX recovery unit.

In addition to above locating TX in existing PX area will also have following

disadvantages-

a. The PX utility system is limiting thus the additional utility such as excess Cooling

water and MP steam for the new facilities will not be available

b. Separate areas of construction (one in NCU another in PX/PTA) will have to be

considered thus spreading construction areas to different location.

c. In case TX is located in PX,as part of integration C7+ product to be routed from

PNCP to PX/PTA and also, the C7-C8 Raffinate streams from the TX plant will

have to be routed back from the PX / PTA plant to PNCP. Instead of the same

toluene and mixed xylene product with lower flow can be routed from PNCP to

PX unit in case TX unit is located in PNCP block. Thus, it was decided to

consider all new facilities in PNCP area.

Considering above, various vacant areas in both NCU and PX/PTA have been identified

and studied and following options have been finalized to locate new units.

Feed Preparation section along with the reactors and associated equipments of

Styrene recovery unit, can be accommodated in the Vacant area on the west of

tank T-2401 and on south of substation #2 plot . For detail refer section 5.2.2.6

(Utilization of vacant space in NCU).

The balance equipments and styrene day tanks can be accommodated in the

area near the methanol tank 11-T-7703 (on the north side of butadiene

extraction unit). For detail refer section 5.2.2.7 (Utilization of identified space

near the methanol tank 11-T-7703 and on the north of Butadiene extraction unit).



Rev. No. 0

Page 37 of 96




Toluene/Xylene extraction unit can be placed in the vacant spaces near to NCU.

For detail refer section 5.2.2.8 (Utilization of vacant space near to NCU).

5.2.2 Utilization of PNCP Area

In PNCP area eight locations were identified as part of the Plot Plan studies to locate the

Feed Preparation unit, the Styrene Recovery unit and the Toluene / Xylene Recovery

units. Details of the locations identified, and the analysis of the study is being detailed in

the following sections. It was also considered that in case feasible, different section can

be located at different available free spaces. This will provide possibility of maximum

utilization of brownfield area but lead to difficulty in construction which has to be tackled

during construction.

5.2.2.1 Feed Preparation Unit

The following locations were identified for placing only the Feed Preparation Unit

separately.

Location No.1 : Area identified close to C-2008 and Analyzer House AHS-03

Finding: Identified space is inadequate to accommodate any equipments of this unit.

Refer attached sketch no. 1

Location No. 2 : Area identified close to STR-02 and Exchanger E-4203

Finding: This identified space is inadequate for the Feed preparation unit mainly from

point of view accommodating the air fin coolers.


Location No. 3: Area identified close to Analyzer House AHS-01 & Reactors R-4601 A/B

Finding: The limitation are as follows:

No approach for existing reactors 11-R-4601A/B by crane, if required, only 3.5 m

clear space available.

Tube bundle removal of 11-E-4601, 11-E-4603 & 11-E-4604 can not be done

from north side as new pipe rack blocks the way for crane..

Analyzer room on the north side will hinder in the erection of equipments.

The future exchanger shown in the technology platform on the west side needs

to be shifted by 6 m more towards the west.

There is very less space for the underground.

With all these constraints, this location still can accommodate all facilities of FPU.




Rev. No. 0

Page 38 of 96




5.2.2.2 Styrene Recovery Unit

The following locations were studied for locating only Styrene Recovery unit

Location No. 4 : Area identified North of Benzene Recovery Unit pipe rack :

Findings:-Considering feed preparation unit as in location no. 3 and Styrene recovery

unit in location no. 4.

Very constrained space for the hard stand, esp. for the column no. C-201.

Erection of equipments shall have to be carried out from the existing road on the

north side. Road will be dysfunctional during the construction stage.

The existing pipe rack on the south side has been utilized for the styrene recovery

unit, with the assumption that sufficient space is available in the existing pipe rack for

the new lines. If sufficient space is not available, then this unit is not feasible at this

location.

It will be very difficult to accommodate all pumps. The space for pump can become

the limiting factor which itself may negate the possibility of unit at this location.

Existing bracings & platform will not allow pumps in 3 bays, thus pumps may have to

be shifted on the south side of the existing rack. Constructability will be an issue.

Locating packages viz. Evaporator package, chemical ejector package may become

constraint, (to be confirmed in detail design stage).


5.2.2.3 Feed Preparation unit and the part of Styrene Recovery unit together: The following

location was studied considering the constraints of treating two separate facilities in one

area.

Location No. 5: Vacant area identified north of Butadiene extraction unit

The area has been examined to locate FPU or the styrene unit tanks.

Findings: The space available for the unit lengthwise (east-west) is only 46.0 meters,

whereas the requirement to accommodate all the equipments is minimum 56.0 meters. .

Therefore it is inadequate for locating FPU.


The same area has been checked to locate the tanks of styrene unit.

Findings: As per OISD guidelines, approach roads to be provided all around the dyked

tanks. But in the layout scheme studied, there is no possibility of road on the north side

of the tanks. Hence this can not be utilized




Rev. No. 0

Page 39 of 96




Location No.7: Vacant area identified adjacent to the Hydrogen Storage & Flare KOD in

the NCU Area

Findings: Based on the detailed evaluations, It was found that it is not possible to use

the plot identified adjacent to the Hydrogen storage & the Flare KOD because of the

following primary reasons:

The plot size is very small leading to constraint in accommodating any significant

portion of the Styrene Recovery unit.

The plot is already having a lot of U/G piping corridors and cable trenches which

will cause hindrance to the Structural foundations.

Existing Hydrogen storage being very near, safety in construction will be an

issue.

With all the above analysis, it is found that locating FPU or Styrene recovery or both

together in the above brownfield areas will have valid constraints.

5.2.2.4 The Styrene Recovery unit, Feed Preparation Unit and Xylene –Toluene Extraction Unit

all at one place.

Location No.8 : Vacant area identified north of Hydrogen & Tail Gas Compressor

House up to north side battery limit of NCU

Analysis of the study:

1. This option is feasible considering the plot area requirements of the three

sections.

2. Constructability will be easier, practical & safe as most of the construction will be

in single area and approachable.

3. A single pipe rack will suffice for all the three units.

4. Overall number of additional hookup for utility connections will be less as the

distribution to all units(FPU, Styrene Recovery, TX recovery will be from common

header



Rev. No. 0

Page 40 of 96




SKETCH NO. 1

Study on Various Options in Existing Layout Location-1

SKETCH NO. 2

Study on Various Options in Existing Layout-Location2



Rev. No. 0

Page 41 of 96




SKETCH NO. 3

Study on Various Options in Existing Layout-Location 3



Rev. No. 0

Page 42 of 96




SKETCH NO. 4




Rev. No. 0

Page 43 of 96




SKETCH NO. 5


SKETCH NO. 6

Study on Various Options in Existing Layout for off-site facilities



Rev. No. 0

Page 44 of 96




5.2.3 Conclusion

Finally based on all the Plot Plan studies carried out, and as desired by owner,

maximum utilization of Brownfield area has been achieved as follows. Please also refer

layout annexure VII. The following general assumptions have been considered in

selecting the plot area which will have to be studied further during execution-:

a. The equipments have been placed as per OISD guidelines only in the absence of

P&ID, No other requirement has been considered.

b. The sizes of equipments mainly vendor packages are assumed which needs to be

firmed up after vendor data during execution.

c. The information of structural foundation details are preliminary

d. The hook ups of piping, underground piping, electrical, instrumentations have not

been studied. Adequacy of scheme studied is subject to easy availability/ feasibility of

all hooks up points.

A. Space at the west side of T2401 and south of sub station #2

Feed Preparation section along with the reactors and associated equipments of Styrene

recovery unit, can be accommodated in the specified area. The specific constraints in

the selecting the plot area are:

a. It is assumed that the existing pipe rack extension in the east- west direction is

structurally feasible in the wake of existing underground piping corridor, cable

trenches.

b. The crane access will be provided from the west side to the unit for the erection of

equipments.

B. Utilization of identified space near the Methanol tank 11-T-7703 and on the north

of Butadiene extraction unit

The balance equipments other than feed preparation and reactors of the Styrene

Recovery unit along with 2 nos. Styrene day tanks have been accommodated in the

area near the methanol tank (on the north side of butadiene extraction unit) subject to

constraints as mentioned in the drawing.

Specific Constraints for the identified plot:

a. The crane access to be provided from the west & east side through the BDEU unit

internal road which is on the south side of the unit for the erection of equipments.

b. The pipe rack hook up has been taken from the existing offsite pipe rack on the north

side. The feasibility of the study is subject to availability of space in offsite rack for all

lines of styrene recovery unit.



Rev. No. 0

Page 45 of 96




C. Space near PGHU

Based on the various options studied it was confirmed that it is not possible to accommodate toluene/Xylene extraction unit in brownfield areas, other than the vacant space near to NCU. Thus area identified on the west of flare knock out drums and extending up to the west side battery limit has been considered for the same.

Specific constraints for this area:

a. It is assumed that the new pipe rack in the west direction between existing flare

K.O.D. and the compressor house is structurally feasible in the wake of existing

underground piping corridor, cable trenches. The actual feasibility of the pipe rack as

planned depends on the existing underground facilities.

b. The crane access to be provided from the south side to the unit for the erection of

equipments.

c. The equipments have been aligned along the pipe rack so as to save space width

wise. The scheme is subject to acceptability of layout, process wise.

Thus all facilities are accommodated as follows-

FPU & PA (phenyl-acetylene ) Selective hydrogenation reactor & associated equipments- Area 41 m x 19.5 m

Balance Styrene recovery unit equipments- Area 48 m x 50 m

TX recovery unit equipments- Area 136 m x 39 m While construction proper safety practices need to be followed as the units will be located in various sections and will be surrounded by operating facilities.

D. Off-site Storage Tank

The new storage tanks will be located to the east of NCU presently marked as fabrication area.



Rev. No. 0

Page 46 of 96




Chapter 6.0 Project Description



Rev. No. 0

Page 47 of 96




6.0 Project Description

6.1 Project Configuration

6.1.1 Unit Facilities

The unit capacities for the new units which are considered for the feasibility study are based on following cases. Design Case: Naphtha Cracker capacity corresponding to 800 KTPA

Option -1: Stand alone Styrene recovery Option -2: Integrated Styrene, Mixed Xylene and Toluene recovery Check case: Naphtha cracker capacity corresponding to 1000 KTPA Option-1: Stand alone Styrene recovery Option-2: Integrated Styrene, Mixed Xylenes and Toluene recovery

6.1.2 Plant Capacity

The capacities of the new units for all the above cases are as follows: Capacity of each unit for the Design Case & Check Case are as follows :

Sl. No

Capacity Design Case (KTPA)

Check Case (KTPA)

1 Styrene Feed Preparation unit (Feed to Styrene FPU)

356 445

2 Styrene Recovery unit (Styrene Product)

17 (20) Note-2

21 (25) Note-2

3 Toluene / Xylene Recovery unit (C7 feed ) applicable for Option -2

220 275

Note

1 All capacity numbers are rounded off. 2. The Styrene recovery capacity indicated are based on 5.1% wt Styrene potential

in feed, which will be the basis for the Feasibility Study for estimating Material Balance, and OPEX, while 6 % wt styrene recovery is considered for CAPEX estimation which are indicated in parentheses.



Rev. No. 0

Page 48 of 96




6.2 Overall Configuration for Various Options

The configuration for the facilities are indicated below-

Flow Scheme for Option-1

Flow Scheme for Option-2

Legend: New Facility Existing Facility

PGHU

Styrene

Recovery unit

Styrene to SBR

PGH

U

Styrene

Recovery Unit

BEU

Styrene to SBR

Toluene to PR/Sales

Xylenes to PR

Toluene/

Xylene

Extraction

Benzene C6-C8

C7+

C7-C8 raffinate

to HPG to NCU/PR

Heavy

Pyrolysis

Gasoline

Feed

Preparation

C5-C7

C9+ Cut

De

C7

De

C8

C8 Cut

Heavy

Pyrolysis

Gasoline

Feed

Preparation

C5-C7

C9+ Cut

De

C7

De

C8

C8 Cut

Light

Pyrolysis

Gasoline

Light

Pyrolysis

Gasoline

C8 raffinate

C8 raffinate

C6-C8 to

BEU



Rev. No. 0

Page 49 of 96




6.3 Process Description

6.3.1 Styrene Recovery Unit

The feed to the Styrene Recovery unit is the Heavy Pyrolysis Gasoline streams generated in the Gasoline Stripper Bottoms of the existing Naphtha Cracker Unit (NCU).

6.3.1.1 Prefractionation Section

The two main columns in the feed Prefractionation Sections are the Deheptaniser Column and the Deoctanizer Columns . The Pygas Feed stream is first sent to the Feed Surge Drum, and then preheated by Deoctanizer overhead vapor before feeding into Deheptanizer column to remove the C7- cut. Deheptanizer is operated under vacuum condition. The Deheptanizer bottoms are introduced to the Deoctanizer to separate C8 styrene concentrate from the C9+ cut. Deheptanizer Overhead product, C7- cut, is condensed and returned to the battery limit for further hydrotreatment. A portion of the Deoctanizer overhead vapor is used for preheating Deheptanizer feed, the left part is condensed in DeC8 condenser. Then the condensate C8 styrene concentrate cut is further fed to the PA hydrogenation reactor section for selective hydrogenation of the phenyl-acetylene compound. The Deoctanizer bottoms are cooled and returned to battery limit for further hydrotreatment. Deoctanizer is operated under vacuum condition. Above is as per the Licensor original proposed scheme. Refer Drawing attached as annexure 2.

Optimized Scheme for Prefractionation Section

As the Feed Preparation Unit is located adjacent to the Stripper Column in the existing NCU unit, the following modifications are proposed on the FEED Pre-fractionation Section :

Requirement of Feed Surge drum and Feed Pumps The Feed stream from Battery limit is the Heavy Pyrolysis Gasoline from Medium Gasoline Pump (11-P-2002A/B) discharge at 4.3 Kg/cm2g & 121 deg C. As per the Licensor’s scheme the feed stream is collected in the Feed Surge Drum (D-103) and then pumped through DC7 Feed Pump P-105A/B before preheating to the DeHeptaniser Column (C-101). The head requirement for the feed Pump is 25 meters. Since Pre-fractionation facilities are to be placed within the existing NCU unit, the Feed surge drum and Pumps will not be required and hence not considered for the study. Requirement of Exchangers C7 Raffinate Cooler (E-106) , C9+ Cut Cooler( E--107 ) & C9+ Cut Trim Cooler (E-108) : The routing proposed for the C7 Raffinate and C9+ Cut Product streams as per the licensor’ s scheme is as follows : a. The C7 cut product stream is cooled in the exchangers E-106 before being routed

to B/L . b. The C9+ cut product stream is cooled in the exchangers E-107 and E-108 before

being routed to B/L .

The Feed preparation units are to be integrated with the existing NCU. Based on the product routing of the C7 Raffinate and C9+ cut products back to the existing Gasoline



Rev. No. 0

Page 50 of 96




product coolers, the new coolers proposed by the Licensor have been eliminated. The C7 & C9 Cut streams shall be joined together along with the C8 Raffinate product and routed back to the existing Gasoline product cooler (11-E-5003) as a single stream to Battery limit.. Though C7 & C9 Cut streams may be at higher temperatures, but C8 Raffinate stream will be joining at much lower temperature and thus making the Gasoline product cooler adequate for total duty. The adequacy of the existing facilities shall be finally established during detailed feasibility studies based on process stream data. The revised Process Scheme proposed for the Feed Preparation unit is attached as Annexure A2 .

6.3.1.2 PA Selective Hydrogenation Sections

The C8 cut contains a small amount of phenyl-acetylene (PA), which is undesirable in the final styrene product. This stream is sent through a selective hydrogenation Reactor, upstream of the extractive distillation unit, where the PA is selectively hydrogenated to styrene. A small amount of styrene is saturated to ethylbenzene at the same time. The overall styrene loss in PA hydrogenation section is controlled within 5 percents. PA selective hydrogenation catalyst can be regenerated. C8 styrene concentrate cut from Deoctanizer is cooled to 45 ºC, and then sent to PA hydrogenation reactor. Two PA selective hydrogenation reactors are used, one is in operation, the other is spare. The hydrogenated reactor effluent free of PA is cooled to 40ºC, then the cooled effluent is sent to the PA hydrogenation Product Separator. The offgas from the separator is sent to fuel gas system or flare header. The liquid effluent is split; one stream is going back to the reaction loop as the recycle feed, in order to keep the space velocity and reactor temperature uplift within required limits. The other stream is sent to the EDC Feed Drum, as feed to the Extractive Distillation Section. The PA hydrogenation reactors can be also operated in series.

6.3.1.3 Extractive Distillation Section

The hydrotreated C8 heart-cut is collected in EDC feed tank, preheated by hot lean solvent, and fed to the Extractive Distillation Column (EDC). In a vapor-liquid operation, the solvent selectively extracts the styrene into the bottoms, while rejecting the other C8 aromatics and non-aromatics components to column OVHD as the raffinate. Stripping steam in injected at the bottom of the column in order to reduce the bottom temperature at the level when polymer formation is avoided; also to allow the overall operation of the column in such a way that regular recirculation cooling water can be use for overhead main condenser instead of chilled water. The EDC column is a packing column and operates under vacuum. The column overhead vapors are condensed in two-stage overhead condensers; the main condenser is using cooling water as cooling medium, while the trim condenser is using chilling water. The condensed liquid is collected in the overhead accumulator. A portion of the overhead is routed back to the column as reflux, while the remaining C8 raffinate is sent to the B.L. A small part of raffinate is sent to Polymer Removal System Water collected overhead is removed via a water boot on the accumulator and sent to the water surge drum. Furthermore, stripping steam originating from the system water balance is injected at the bottom of the column to assist in the extractive distillation operation and to reduce the temperature at the bottom of the column. The EDC column is reboiled using LP steam. The rich solvent withdrawn from the bottom of the EDC is fed to the Solvent Recovery Column (SRC). The SRC is a packing column that operates under vacuum. In



Rev. No. 0

Page 51 of 96




the SRC styrene will be separated from the solvent producing a lean solvent quality required for the extractive distillation operation in the bottoms of the column. The stripping steam originating from the system water balance is injected to the base of the column to assist in the stripping operation. The SRC column is reboiled using IP steam. Styrene product, stripped out from the rich solvent is collected at the top of the SRC column and condensed in the overhead condenser before being sent to the accumulator. Water collected overhead is removed via the water boot on the accumulator and sent to the water surge drum. Part of the overhead hydrocarbons is used as reflux while the rest is withdrawn as styrene extract product, which will be further processed into the Drying Column to remove free water in styrene. Lean solvent from the bottom of SRC is sent through a series of heat exchangers to recover heat before being routed to the top of the EDC. First, the lean solvent is used to generate stripping steam for the EDC and SRC. The solvent is then used as heating medium to preheat the feed to EDC. Finally, the lean solvent is cooled down to the required temperature before being introduced to the EDC. A small part of the lean solvent which contains some heavy components is directed to Polymer Removal System.

6.3.1.4 Dryers and Color Treatment Section

The styrene extract, overhead product of SRC, is sent to the Drying Column. The water will be vaporized from the styrene extract in the column. The drying column overhead vapor including some styrene and water is routed to the SFC condenser, where the water will be removed at the top of Styrene Finishing Column (SFC) receiver. The dried styrene extract is sent to the Drying Column Bottom Cooler to be cooled down to about 40 °C, temperature required for color treatment operation. The styrene extract mixed with inhibitors and color treatment chemical is supplied to the Stir Drum where the reaction for color bodies’ removal is completed.

6.3.1.5 Styrene Finish Column Section

After drying and chemical treatment operations the styrene extract is sent to the SFC for final purification. The SFC is a packing column that operates under vacuum. This operation removes the remaining impurities, and produces a polymer-grade styrene. The overhead vapor is condensed using cooling water and is accumulated in SFC OVHD Receiver. The water is separated and sent to the water surge drum, while the organic layer is refluxed back to the column, except a small portion which is purged to the BL This will allow to control the removal of light color bodies which need to be separated from the styrene products. The styrene product is side withdrawn from SFC and pumped to storage tanks after is cooled down to storage temperature by using cooling water and chilled water. The SFC bottoms containing heavy components and styrene is further processed in a wiped falling film evaporator for styrene recovery. The styrene is returned to the bottom of the SFC while the heavies recovered as bottom product are sent to B.L. Styrene Finishing Column is reboiled by using LP steam.

6.3.1.6 Solvent Regeneration and Steam Generation Section

The process water containing traces of light hydrocarbons from the EDC Overhead Receiver, SRC Overhead Receiver and SFC Overhead Receiver is collected in the Water Surge Drum and is pumped to the top of the Water Stripper. Solvent and Water from HRS is fed in the middle section of Water Stripper. In Water Stripper, any trace amounts of hydrocarbon contained in the water phase are stripped by the ascending vapor generated in Steam Generator. The stripper overhead vapor including stripped hydrocarbons is routed to the EDC Condenser for hydrocarbon recovery. The steam generator kettle exchanger is



Rev. No. 0

Page 52 of 96




compose of two bundles, one bundle vaporizing the water by using hot lean solvent as heating medium, and a second bundle for vaporizing the remaining process water by using LP steam as a heating medium . The stripping steam generated in Steam Generator is used to assist the stripping process in the EDC column, SRC column and the vaporization of solvent in the solvent regenerator. The solvent remaining at the bottom of the Steam Generator split into two direction, one part is sent to the Solvent Generator, while the remaining is returned to SRC bottom. In the solvent regenerator the heavy decomposition products of solvent degradation are removed from the solvent. The heavies are purged periodically, while the regenerated solvent is returned back to the solvent recovery column. Stripping steam is utilized to assist in the separation of the heavies from the solvent, thus integrating the solvent recovery and regeneration operations and avoiding the use of a separate vacuum system or equipment. Solvent Regenerator is using IP steam as heating medium.

6.3.1.7 Polymer Removal System Section

A small amount of cooled solvent from downstream of lean solvent cooler is processed for removal of possible styrene polymers, in order to keep the solvent at the required quality. The solvent slip stream is mixed with the raffinate to facilitate the removal of the polymers from the solvent phase. Water flowrate from the 2nd Stage Separator is mixed with the solvent-raffinate stream. The solvent-water-raffinate mixture is entering the 1st Stage Separator where the two phases are separated. The water phase dissolving the solvent is separated as the lower liquid layer, while the polymer extracted by the raffinate is separated as the organic top layer. The bottom water-solvent layer is withdrawn and sent to the Water Stripper. The organic layer consisting of polymer dissolved in the raffinate stream is further water washed for removing and recovering the traces of solvent which are carried by the polymer raffinate stream. Fresh water from the water surge drum is used as water wash of the organic phase. The water layer containing all the solvent from the organic feed is separated at the bottom of the 2nd Stage Separator, and sent back to 1st Stage Separator. The top layer of the Raffinate/Polymer Extraction Drum consisting of polymer-raffinate mixture, free of solvent is sent out to Battery Limit.

6.3.1.8 Styrene and Solvent Storage Section

This section is mainly used for styrene products, fresh solvent make-up and wet solvent storage. For minimizing styrene polymerization and avoiding plugging, several filtering systems and inhibitor injection systems are included along the Styrene Recovery Unit.

6.3.2 Toluene/Xylene Extraction Unit

The feed to the Toluene / Xylene (TX) Recovery unit is the hydrogenated Pyrolysis Gasoline stream generated in the existing PGHU of Naphtha Cracker Unit (NCU).

Toluene – Xylene Recovery unit does not include a Xylene splitter to separate out mixed xylene with in the proposed TX recovery unit. The requirement of splitter can be finalized after establishing adequacy of the facilities within the PX . Two options for the TX unit have been proposed by the Licensor: Option A : The flow scheme has Toluene- Xylene recovery along with a Fired heater with heat integration between Toluene and Xylene columns considering limitations in HP steam availability.



Rev. No. 0

Page 53 of 96




Option B : With HP steam being utilized in the Xylene column Licensor’s option B has been shortlisted as-

Option A has requirement of a higher capital cost.

A heater with considering smaller duty (3.3 MMkcal/h) will have lower efficiency and higher OPEX.

An additional Fired Heater will calls for additional safety requirement and additional stack

Space requirement will increase additionally to take care of statutory requirement.

Any further optimization to integrate with the existing separation facilities, shall be examined at the time of job execution or detailed feasibility studies. The option B will be require HP steam of the order of the 6.2 TPH which is considered to be available in existing NCU complex

6.3.2.1 Prefractionation Section

The C7+ feed from existing Dehexanizer bottoms of Benzene Extraction Unit is first preheated with TX cut from the overheads of C8/C9+ Prefractionator Column through the feed preheater (E-101 A/B) and then fed to the middle of the C8/C9+ prefractionator column (C-101), where TX cut is separated from C9+ heavies. The column overhead vapor is condensed in an overhead condenser (E-102) and collected in overhead receiver (D-101). The condensed liquid is partly sent to column as reflux and remaining is withdrawn as TX cut by reflux pump (P-101 A/B).

6.3.2.2 Extractive Distillation Section

The TX cut is further sent to BTX extractive distillation unit for separating aromatics after exchanging heat with feed in E-101 A/B. During startup or if extractive distillation is not in operation, then TX cut is sent to storage after cooling down in TX cut cooler (E-104A/B). The C8/C9+ prefractionator column is reboiled using MP steam in reboiler (E-103). The prefractionator bottoms consisting mainly of C9+ heavies is pumped by bottoms pump (P-102 A/B) and mixed with C9+ stream from Xylene column. The combined C9+ heavies stream is sent to storage after being cooled down to storage temperature in C9+ heavies cooler (E-105) and trim cooler (E-106). The TX cut from the overhead of the prefractionator is preheated by exchanging heat with circulating hot lean solvent in EDC feed preheater (E-209). The heated hydrocarbon feed is introduced at the middle of the column, while the lean solvent is introduced close to the top of the Extractive Distillation Column (EDC) (C-201). In a vapor-liquid operation the solvent will extract the aromatics to the bottom of the column, while rejecting the non-aromatics to the top as raffinate. The raffinate vapors are condensed in EDC condenser (E-202) and collected into EDC overhead receiver (D-201). A portion of the liquid is sent back to the EDC as reflux, and the remaining stream is cooled to the storing temperature in Raffinate cooler (E-211) and sent to the battery limit (BL) as raffinate product by EDC reflux pump (P-201 A/B). The EDC is reboiled (E-203) using MP steam as heating medium. The rich solvent containing solvent and aromatics is withdrawn by EDC Btms pump (P-203 A/B) from the bottom of EDC and feeds the solvent recovery column (SRC) (C-202). Aromatic hydrocarbons are separated from the solvent at the top of the column. The overhead aromatics vapors are condensed in SRC condenser (E-204) and further cooled in SRC trim/ovhd cooler (E- 205), and then collected into the SRC overhead receiver (D-202). A portion of hydrocarbon liquid from the receiver is sent back to SRC



Rev. No. 0

Page 54 of 96




(C-202) as reflux, the remaining portion, as the extract product from extractive distillation unit, is sent to post fractionation section for separating high purity products. SRC is reboiled by MP steam in stab-in type SRC reboiler (E- 206). Lean solvent from bottom of the SRC (C-202) is pumped back to EDC (C-201) using SRC Btms pump (P-206 A/B). The SRC operates under moderate vacuum conditions to minimize the boiling point at the base of the column. Furthermore, stripping steam, originating from the water balance of the system, is injected into the base of the column to assist in the stripping operation. The hot lean solvent from the bottom of the SRC passes through several heat exchangers for exchanging heat with different streams, thereby significantly reducing the energy consumption of the process. The lean solvent is used first as heating medium of the EDC Side reboiler (E- 212). The lean solvent heat integration continues with stripping steam generated in Steam generator (E-207) followed by feed preheating in EDC feed preheater (E-209) and process water preheating in Water preheater (E-210). Finally the lean solvent is cooled down to the required solvent feed temperature in Lean Solvent Cooler (E-201). The water collected from the boots of the EDC overhead receiver (D-201) and SRC overhead receiver (D-202) is pumped to the process Water Surge drum (D-203). From here the water is pumped by Decant water pump (P-207 A/B) to the Water preheater (E-210) first and then to Steam generator (E-207) for stripping steam generation. A part of process water from Water preheater is directed to bottom of EDC to strip of any heavy boiling non-aromatics to the overhead of the column. The stripping steam generated in Steam generator is directed to the solvent regenerator and then continues to the SRC as steam-solvent mixture. The steam is used for stripping the aromatics in the SRC, and thus maintains a closed loop for the system water. The aromatics extract from Extractive distillation section is first preheated in Extract preheater-1 (E-301) using heat from Toluene Column side draw stream and further heated in Extract preheater-2 (E-302) with mixed xylenes product from Xylene Column overhead. The extract is fed in the middle of Toluene Column (C-301) where high purity toluene is separated from mixed xylenes. The overhead vapors from Toluene Column (C-301) are condensed in Toluene Column ovhd condenser (E-303) and the condensed liquid is collected in Toluene Column ovhd receiver (D-301). The water in extract feed separates out in the water boot of ovhd receiver (D-301) and sent by gravity flow to Water Surge Drum (D-203) in the extractive distillation section to maintain a closed loop. The Toluene Column is reboiled partly using overhead vapors from Xylene Column in Toluene Column reboiler exchanger (E-304 A) and partly using MP steam in Toluene Column reboiler (E-304 B). Toluene Column bottoms pump (P-303 A/B) is used to pump bottoms to middle of the Xylene column (C-302). The mixed xylenes rich stream enters the Xylene Column (C-302) where the trace C9+ components are separated to obtain high purity mixed xylene product. Any traces of solvent entrained in the extract product are separated also at the bottom of the column guaranteeing a solvent-free xylene product at the top of the column. The overhead vapors from Xylene column are partly sent to Toluene Column for reboiling the column; a small fraction of the overhead vapor stream is sent to air cooled Xylene Column condenser to help control the pressure in the Xylene column. The condensed liquid is collected in Xylene Column overhead receiver (D-302) and pumped by Xylene Column reflux pump (P-304 A/B) partly back to the column as reflux and remaining is withdrawn as mixed xylenes product. The mixed xylenes product is first cooled down by exchanging heat with aromatics extract feed in Extract preheater-2 (E-302) and later in air cooled Xylene product cooler (E-308) and lastly in water cooled Xylene product trim cooler (E-309) to storage



Rev. No. 0

Page 55 of 96




temperature before sending to storage. The Xylene Column is reboiled in fuel fired Xylene column reboiler heater. The recirculation through the reboiler heater is maintained using the reboiler circulation pump (P-305 A/B). Xylene Column bottoms stream consist mainly of C9+ heavies is withdrawn and mixed with C9+ heavies stream from C9+ splitter column bottoms for further cooling and storage.

6.3.2.3 Solvent Storage Section and Flare System

The operation of the Extractive Distillation Unit also requires a solvent storage facility consisting of two solvent tanks, one solvent sump tank, one wet solvent cooler and a transfer pump. The solvent is loaded / unloaded to / from the process unit in plant solvent tank TK-201 and wet solvent tank TK-202. Drains from Extraction section are sent to solvent sump D-205 located underground at the lowest point of the plant. A solvent cooler E-213 is also provided for cooling down wet solvent before sending it to the storage facilities. One additional vessel, D-204, is provided as solvent vent drum to collect liquids from the extraction unit PSV’s where there is a high probability that a release could result in a loss of the valuable liquid solvent to the flare. From D-204, the liquid can be directed to the solvent drain, which is collected in the solvent sump, D-205, for eventual recovery.



Rev. No. 0

Page 56 of 96




6.4 Material Balance

6.4.1 Overall Material Balance

The overall material balances for the Styrene Recovery Unit and Toluene – Xylene Extraction Unit has been worked out considering the Styrene potential as indicated by the NCU licensor LUMMUS and further information from Licensor of Styrene and TX Recovery. The Effective feed to TX recovery (through Benzene recovery unit)is based on the actual reduction of the Heavy Pyrolysys Gasoline (HPG) feed to PGHU after extraction of styrene in the new SR unit. The original HPG feed before Styrene Implementation to PGHU is 44905.8 kg/hr which will be reduced to 42226.4 kg/hr with implementation of the Styrene recovery. The C7 Raffinate , C8 Raffinate and C9+ cut streams are recycled back to PGHU as feed. The main product from the Styrene Recovery unit is 2066.6 kg/hr of Styrene. Other Byproducts from styrene Recovery unit are the Residue, Heavies and offgases. The Feed to the Toluene / Xylene (T/X) Recovery unit is the C7+ Raffinate cut from Dehexanizer bottoms of BEUunit. This stream is considered based on LUMMUS Material Balance and considering 5.1 wt% Styrene Extraction from Heavy Gasoline. The actual flow from Dehexanizer bottoms before Styrene Implementation is 29830 kg/hr which is C7+ cut. It is assumed that effective feed (2279.4 Kg/hr) to SR unit (C8) is recovered from C7+ cut from Dehexanizer bottoms. Hence the effective feed to T/X unit is 27550 kg/hr, which is capable of producing 13877 kg/hr of Toluene and 7713 kg/hr of Xylene. Other byproduct from T/X unit are C7C8 non-aromatic Raffinate , Toluene drag and C9heavies cut. The estimated overall material balance for Standalone Styrene recovery and integrated Styrene and Toluene/ Mixed Xylene recovery is given in table:



Rev. No. 0

Page 57 of 96




Table 6.4.1.1: Overall Material Balance

Note 1. C7 and C8 Raffinates from both units are combined together to form one product , as it

can be recycled back to the NCU unit as feed. 2. Total hydrogen is calculated considering the hydrogen saving in PGHU due to

implementation of styrene recovery unit.

As per IOCL, C9, Residue and Heavies products from Styrene Recovery unit and C9 + heavies + Toluene drag from Toluene / Xylene recovery unit are combined to form a single product C9+ streams , which can be routed to the HSD pool .

Sl. No.

Feed Streams / Product Streams





Feed Streams

1 HPG 356046 356046 445057 445057

2 C7 feed to TX 220400 275500

3 Hydrogen (note-2) 38 38 47 47

4 Chemicals 330 330 412 412

Total 356413 576813 445516 721016

Product Streams

5 Offgas 38 38 47 47

6 Styrene 16532 16532 20665 20665

7 Toluene 111000 138750

8 Mixed Xylene 61700 77125

9 C9+ Streams 77610 84210 97012 105262

10 C7-C8 Raffinate 262234 303334 327792 379167

Total 356413 576813 445516 721016



Rev. No. 0

Page 58 of 96




6.4.2 Styrene Recovery unit

6.4.2.1 Unit Material Balance

The Material Balance is as provided by the unit Licensor.

Table 6.4.2.1.1: 5.1% Styrene Potential/Recovery in Feed (HPG)

Feeds MTA Products MTA

Pygas Feed 356,046 C7- Cut 195,958

Hydrogen 38 C9+ Cut 75,578

*Chemicals 329 Raffinate 66,275

Off Gas 38

Styrene Product 16,533

Residue 420

Heavies 1,611

Total 356,413 Total 356,413

Table 6.4.2.1.2: 6.0 % Styrene Potential/Recovery in Feed (HPG)

Feeds MTY Products MTY

Pygas Feed 356,046 C7- Cut 192,210

Hydrogen 38 C9+ Cut 74,708

*Chemicals 460 Raffinate 66,840

Off Gas 38

Styrene Product 20,275

Residue 556

Heavies 1,916

Total 356,543 Total 356,543

* Chemicals include GT-A200 & Flux oil



Rev. No. 0

Page 59 of 96




6.4.2.2 Compositional Material Balance

A. 5.1% Styrene Potential/Recovery in Feed (HPG) Pre-fractionation Section

Component DeC7 Feed C7- Cut C9+ Cut C8 Cut (PA Reactor Feed)

kg/hr wt% kg/hr wt% kg/hr wt% kg/hr wt%

HYDROGEN 0 0 0 0 0 0 0 0

METHANE 0 0 0 0 0 0 0 0

C4 (P,O,N) 49.5 0.11 49.5 0.2 0 0 0 0

C5 (P,O,N) 845.6 1.9 845.6 3.45 0 0 0 0

C6 (P,O,N) 2458.6 5.52 2458.6 10.04 0 0 0 0

C7 (P,O,N) 2823.1 6.34 2819.3 11.51 0 0 3.8 0.04

C8 (P,O,N) 1516 3.41 848.7 3.46 0 0 667.3 6.32

C9 (P,O,N) 33.5 0.08 0 0 0.5 0.01 32.9 0.31

C10+ (P,O,N) 954.2 2.14 0 0 954.2 10.1 0 0

BENZENE 5645.5 12.68 5645.5 23.05 0 0 0 0

TOLUENE 11803.6 26.52 11643.5 47.53 0 0 160.1 1.52

EBENZENE 2849.7 6.4 122.5 0.5 0.1 0 2727.2 25.82

MXYLENE 2339.6 5.26 26 0.11 0.9 0.01 2312.6 21.89

PXYLENE 1006.5 2.26 17.6 0.07 0.2 0 988.8 9.36

OXYLENE 1426.6 3.21 1.9 0.01 42.9 0.45 1381.8 13.08

STYRENE 2240.1 5.03 15.3 0.06 9.4 0.1 2215.4 20.97

A9+ 8460.2 19.01 0 0 8439 89.33 21.1 0.2

PHACETYL 53.4 0.12 0.7 0 0 0 52.6 0.5

CHEMICALS 0 0 0 0 0 0 0 0

Total 44505.7 100 24494.8 100 9447.3 100 10563.7 100



Rev. No. 0

Page 60 of 96




Styrene Extraction Section Compositional Material Balance

Components C8 Cut Hydrogen Off Gas Raffinate


HYDROGEN 0 0 3.3 70.48 0.6 11.80 0 0

METHANE 0 0 1.4 29.52 1.4 28.89 0 0

C4 (P,O,N) 0 0 0 0 0 0 0 0

C5 (P,O,N) 0 0 0 0 0 0 0 0

C6 (P,O,N) 0 0 0 0 0 0 0 0

C7 (P,O,N) 3.8 0.04 0 0 0 0.19 3.7 0.04

C8 (P,O,N) 667.3 6.32 0 0 0.6 13.09 652.5 7.88

C9 (P,O,N) 32.9 0.31 0 0 0 0.09 32.2 0.39

`C10+ (P,O,N) 0 0 0 0 0 0 0 0

BENZENE 0 0 0 0 0 0 0 0

TOLUENE 160.1 1.52 0 0 0.3 7.4 156.3 1.89

EBENZENE 2727.2 25.82 0 0 0.8 17.9 2757.3 33.28

MXYLENE 2312.6 21.89 0 0 0.5 10.38 2263.3 27.32

PXYLENE 988.8 9.36 0 0 0.2 4.95 967.7 11.68

OXYLENE 1381.8 13.08 0 0 0.2 4.4 1351.9 16.32

STYRENE 2215.4 20.97 0 0 0 0.87 80 0.97

A9+ 21.1 0.2 0 0 0 0.04 19.3 0.23

PHACETYL 52.6 0.5 0 0 0 0 0 0

Poly-styrene 0 0 0 0 0 0 0 0

Chemicals 0.0 0.00 0.0 0.00 0.0 0.00 0.0 0.00

Total 10563.7 100.00 4.7 100.00 4.7 100.00 8284.4 100.00



Rev. No. 0

Page 61 of 96





Components Styrene Chemicals Residue Heavies


HYDROGEN 0 0 0 0 0 0 0 0

METHANE 0 0 0 0 0 0 0 0

C4 (P,O,N) 0 0 0 0 0 0 0 0

C5 (P,O,N) 0 0 0 0 0 0 0 0

C6 (P,O,N) 0 0 0 0 0 0 0 0

C7 (P,O,N) 0 0 0 0 0 0 0.1 0.04

C8 (P,O,N) 0 0 0 0 0 0 14.1 7

C9 (P,O,N) 0 0 0 0 0 0 0.7 0.35

C10+ (P,O,N) 0 0 0 0 0 0 0 0

BENZENE 0 0 0 0 0 0 0 0

TOLUENE 0 0 0 0 0 0 3.4 1.68

EBENZENE 0 0 0 0 0 0 59.5 29.56

MXYLENE 0 0 0 0 0 0 48.8 24.25

PXYLENE 0 0 0 0 0 0 20.9 10.37

OXYLENE 0.4 0.02 0 0 0 0.02 29.2 14.49

STYRENE 2064.9 99.92 0 0 11.1 21.22 1.8 0.89

A9+ 1.1 0.05 0 0 0.2 0.45 0.4 0.21

PHACETYL 0.1 0.01 0 0 0 0 0 0

Poly-styrene 0 0 0 0 0 0 22.5 11.17

Chemicals 0.0 0 41.1 100.00 41.1 78.31 0.0 0.00

Total 2066.5 100.00 41.1 100.00 52.5 100.00 201.4 100.00



Rev. No. 0

Page 62 of 96




B. 6.0 % Styrene Potential/Recovery in Feed (HPG) Pre-fractionation Section

Component DeC7 Feed C7- Cut C9+ Cut C8 Cut (PA Reactor Feed)


HYDROGEN 0 0 0 0 0 0 0 0

METHANE 0 0 0 0 0 0 0 0

C4 (P,O,N) 49.3 0.11 49.3 0.21 0 0 0 0

C5 (P,O,N) 836.5 1.88 836.5 3.48 0 0 0 0

C6 (P,O,N) 2436.1 5.47 2436.1 10.14 0 0 0 0

C7 (P,O,N) 2796.5 6.28 2792.6 11.62 0 0 3.9 0.04

C8 (P,O,N) 1511.4 3.4 774.7 3.22 0 0 736.8 6.61

C9 (P,O,N) 32.9 0.07 0 0 0.4 0 32.5 0.29

C10+ (P,O,N) 943.9 2.12 0 0 943.9 10.11 0 0

BENZENE 5588.5 12.56 5588.5 23.26 0 0 0 0

TOLUENE 11679.7 26.24 11515.9 47.93 0 0 163.8 1.47

EBENZENE 2816.5 6.33 24 0.1 0.1 0 2792.4 25.06

MXYLENE 2313.7 5.2 3.5 0.01 0.7 0.01 2309.4 20.73

PXYLENE 996.7 2.24 2.6 0.01 0.1 0 993.9 8.92

OXYLENE 1410.5 3.17 0.2 0 35.5 0.38 1374.7 12.34

STYRENE 2669.6 6 2.4 0.01 9.3 0.1 2657.9 23.86

A9+ 8370.7 18.81 0 0 8348.4 89.4 22.3 0.2

PHACETYL 53.4 0.12 0.1 0 0 0 53.2 0.48

CHEMICALS 0 0 0 0 0 0 0 0

Total 44505.7 100 24026.3 100 9338.5 100 11140.9 100



Rev. No. 0

Page 63 of 96





Components C8 Cut Hydrogen Off Gas Raffinate


HYDROGEN 0 0 3.3 70.48 0.4 8.91 0 0

METHANE 0 0 1.4 29.52 1.4 28.94 0 0

C4 (P,O,N) 0 0 0 0 0 0 0 0

C5 (P,O,N) 0 0 0 0 0 0 0 0

C6 (P,O,N) 0 0 0 0 0 0 0 0

C7 (P,O,N) 3.9 0.04 0 0 0 0.2 3.8 0.05

C8 (P,O,N) 736.8 6.61 0 0 0.7 14.76 717.7 8.59

C9 (P,O,N) 32.5 0.29 0 0 0 0.08 31.7 0.38

C10+ (P,O,N) 0 0 0 0 0 0 0 0

BENZENE 0 0 0 0 0 0 0 0

TOLUENE 163.8 1.47 0 0 0.4 7.84 159.4 1.91

EBENZENE 2792.4 25.06 0 0 0.9 18.71 2816.8 33.71

MXYLENE 2309.4 20.73 0 0 0.5 10.52 2251.5 26.95

PXYLENE 993.9 8.92 0 0 0.2 5.06 969 11.6

OXYLENE 1374.7 12.34 0 0 0.2 4.43 1339.6 16.03

STYRENE 2657.9 23.86 0 0 0 0.51 45.1 0.54

A9+ 22.3 0.2 0 0 0 0.04 20.4 0.24

PHACETYL 53.2 0.48 0 0 0 0 0 0

Poly-styrene 0 0 0 0 0 0 0 0

Chemicals 0 0 0 0 0 0 0 0

Total 11140.9 100 4.7 100 4.7 100 8355 100



Rev. No. 0

Page 64 of 96





Components Styrene Chemicals Residue Heavies


HYDROGEN 0 0 0 0 0 0 0 0

METHANE 0 0 0 0 0 0 0 0

C4 (P,O,N) 0 0 0 0 0 0 0 0

C5 (P,O,N) 0 0 0 0 0 0 0 0

C6 (P,O,N) 0 0 0 0 0 0 0 0

C7 (P,O,N) 0 0 0 0 0 0 0.1 0.04

C8 (P,O,N) 0 0 0 0 0 0 18.4 7.66

C9 (P,O,N) 0 0 0 0 0 0 0.8 0.34

C10+ (P,O,N) 0 0 0 0 0 0 0 0

BENZENE 0 0 0 0 0 0 0 0

TOLUENE 0 0 0 0 0 0 4.1 1.7

EBENZENE 0 0 0 0 0 0 72 30.05

MXYLENE 0 0 0 0 0 0 57.5 23.99

PXYLENE 0 0 0 0 0 0 24.7 10.33

OXYLENE 0.7 0.03 0 0 0 0.02 34.2 14.29

STYRENE 2532.4 99.92 0 0 11.8 17 1.3 0.53

A9+ 1.2 0.05 0 0 0.2 0.25 0.5 0.22

PHACETYL 0.1 0 0 0 0 0 0 0

Poly-styrene 0 0 0 0 0 0 26 10.86

Chemicals 0 0 57.5 100 57.5 82.73 0 0

Total 2534.4 100 57.5 100 69.5 100 239.5 100



Rev. No. 0

Page 65 of 96




6.4.3 Toluene-Xylene Extraction Unit

6.4.3.1 Unit Material Balance

The Material Balance is as provided by the Licensor.

A. 5.1% Styrene Potential/Recovery in Feed (HPG)

Stream MTA Stream MTA

C7+ feed 222,100 Toluene product 111,000

Mixed Xylene product 61,700

Raffinate 42,900

Toluene drag 900

C9+ heavies 5,700

Total 222,100 Total 222,100

B. 6.0% Styrene Potential/Recovery in Feed (HPG)

Stream MTA Stream MTA

C7+ feed 218,400 Toluene product 111,000

Mixed Xylene product 58,000

Raffinate 42,900

Toluene drag 900

C9+ heavies 5,700

Total 218,400 Total 218,400



Rev. No. 0

Page 66 of 96




6.4.3.2 Compositional Material Balance

A. 5.1% Styrene Potential/Recovery in Feed (HPG)

Components C7+ Feed Toluene Product Xylene Product Raffinate

Kg/h wt. % Kg/h wt. % Kg/h wt. % Kg/h wt. %

C6 Naphthenes 6 0.02 0 0 0 0 6 0.12

Benzene 17 0.06 6 0.05 0 0 4 0.07

C7 Paraffins 2161 7.78 0 0 0 0 2161 40.35

C7 Naphthenes 1558 5.61 21 0.15 0 0 1537 28.71

Toluene 13958 50.27 13844 99.76 13 0.17 0 0.01

C8 Paraffins 991 3.57 0 0 0 0 991 18.51

C8 Naphthenes 660 2.38 2 0.01 4 0.05 653 12.2

Ethylbenzene 1903 6.85 4 0.03 1883 24.41 2 0.04

p-Xylene 1239 4.46 1 0 1224 15.86 0 0

m-Xylene 3366 12.12 1 0.01 3318 43.02 0 0

o-Xylene 1299 4.68 0 0 1239 16.06 0 0

C9+ non-aromatics

30 0.11 0 0 29 0.38 0 0

C9+ aromatics 577 2.08 0 0 3 0.04 0 0

Total, kg/h 27765 100 13877 100 7713 100 5355 100

Components Kg/h

Toluene drag C9+ heavies

Kg/h wt. % Kg/h wt. %

C6 Naphthenes 0 0 0 0

Benzene 6 6.04 0 0

C7 Paraffins 0 0 0 0

C7 Naphthenes 1 0.68 0 0

Toluene 100 93.29 0 0.06

C8 Paraffins 0 0 0 0.02

C8 Naphthenes 0 0 1 0.1

Ethylbenzene 0 0 15 2.06

p-Xylene 0 0 15 2.08

m-Xylene 0 0 47 6.65

o-Xylene 0 0 60 8.42

C9+ non-aromatics

0 0 1 0.1

C9+ aromatics 0 0 573 80.5

Total, kg/h 107 100 712 100



Rev. No. 0

Page 67 of 96




B. 6.0% Styrene Potential/Recovery in Feed (HPG)

Components C7+ Feed Toluene Product Xylene Product Raffinate

Kg/h wt. % Kg/h wt. % Kg/h wt. % Kg/h wt. %

C6 Naphthenes 6 0.02 0 0 0 0 6 0.12

Benzene 17 0.06 6 0.05 0 0 4 0.08

C7 Paraffins 2161 7.92 0 0 0 0 2161 40.31

C7 Naphthenes 1558 5.71 16 0.12 0 0 1541 28.75

Toluene 13958 51.13 13845 99.79 12 0.17 0 0.01

C8 Paraffins 991 3.63 0 0 0 0 991 18.48

C8 Naphthenes 660 2.42 1 0.01 3 0.04 656 12.23

Ethylbenzene 1436 5.26 3 0.02 1420 19.59 1 0.03

p-Xylene 1239 4.54 1 0 1224 16.88 0 0

m-Xylene 3366 12.33 1 0.01 3318 45.78 0 0

o-Xylene 1299 4.76 0 0 1239 17.1 0 0

C9+ non-aromatics

30 0.11 0 0 29 0.4 0 0

C9+ aromatics 577 2.11 0 0 3 0.04 0 0

Total, kg/h 27298 100 13873 100 7247 100 5361 100

Components Kg/h

Toluene drag C9+ heavies

Kg/h wt. % Kg/h wt. %

C6 Naphthenes 0 0 0 0

Benzene 6 6 0 0

C7 Paraffins 0 0 0 0

C7 Naphthenes 1 0.54 0 0

Toluene 100 93.46 0 0.06

C8 Paraffins 0 0 0 0.02

C8 Naphthenes 0 0 1 0.1

Ethylbenzene 0 0 11 1.56

p-Xylene 0 0 15 2.09

m-Xylene 0 0 47 6.68

o-Xylene 0 0 60 8.47

C9+ non-aromatics

0 0 1 0.1

C9+ aromatics 0 0 574 80.93

Total, kg/h 107 100 709 100



Rev. No. 0

Page 68 of 96




6.4.4 Hydrogen Saving in PGHU

Implementation of Styrene recovery results in saving in hydrogen in the PGHU which has been considered in the overall material balance. The hydrogen benefit has been considered corresponding to stoichiometrical proportion to styrene recovered. Saving will be as below given for two case -

Table 6.4.4.1: H2 saving 5.1% Styrene Potential/Recovery in Feed (HPG)

Descriptin MTA Unit

Styrene Recovered

16533 MTPA

2066.6 Kg/h

19.9 kgmol /h

H2 saving in PGHU

19.9 kgmol/h

39.7 kg/hr

317.9 MTPA

Table 6.4.4.2: H2 Saving 6.0 % Styrene Potential/Recovery in Feed (HPG)

Descriptin MTA Unit

Styrene Recovered

20275 MTPA

2534.4 Kg/h

24.4 kgmol /h

H2 saving in PGHU

24.4 kgmol/h

48.7 kg/hr

389.9 MTPA



Rev. No. 0

Page 69 of 96




6.5 Utilities Description

6.5.1 Utility Requirement

The utility requirement for styrene recovery unit and Tolene Xylene Recovery unit is estimated based on the requirements specified in the preliminary proposals provided by the Licensor and for off-site facilities EIL in-house estimates have been used. Basis for estimation of Utility requirements a. For Utility Requirement Licensor Data has been followed corresponding to NCU

Capacity 800 KTPA. For Capacity corresponding to 1000 KTPA, proration factor has been suitably used.

b. For Chilled Water requirement a new Chiller facility shall be provided.

c. Suitable margin around 15% has been considered on Utility requirement as the data base is Preliminary Proposal by Licensor.

d. For Offsite facility separate estimates has been done based on EIL inhouse data.

e. With modification proposed by EIL in utilizing existing coolers, the utility (Cooling water) requirement will be marginally lower than estimated .

f. For existing PNCP unit, the augmented requirement of utilities to achieve 1000 KTPA capacity has not been estimated and indicated.

g. For units, Licensor data has been used as such as no specific information for each equipment e.g. duty of heat exchanger were available.

The utility requirement was estimated for the following four options as per design basis: a. Design Case Option-1: Stand Alone Styrene Recovery Project at 800 KTPA

b. Design Case Option-2: Intergrated Styrene Recovery and Mixed Xylenes recovery

Project at 800 KTPA

c. Check Case Option-1: Stand Alone Styrene Recovery Project at 1000 KTPA

d. Check Case Option-2: Intergrated Styrene Recovery and Mixed Xylenes recovery Project at 1000 KTPA

The additional utility requirement will be made available from existing PNCP facilities and hookups will be provided from the PNCP headers. However the requirement of additional utilities is small compared to existing Utilities system capacities. Utility Requirement for the new facilities based on Licensor’s data corresponding to 800 KTPA NCU capacity is as follows:



Rev. No. 0

Page 70 of 96




Table 6.5.1.1: Utility Requirement

Unit Area Styrene Recovery

Unit TX Plant Offsite Area

Utilities Normal Design Normal Design Normal Design

HP Steam 6.2 7.1

MP Steam 20.5 23.6 33.0 38.0

LP Steam 8.6 9.9 0.0

Cooling Water 682.6 785.0 85.0 97.8

Chilled Water 6.3 7.2 0.0

Power 314.2 361.3 321.0 369.2 13.0 14.9

BFW 0.5 0.6 0.0

Nitrogen 19.6 22.5 0.0 200.0 230.0

Instrument Air 250.0 287.5 200.0 230.0 20.0 23.0

1. Cooling Water, HP steam, MP steam, LP steam, BFW for ISBL : As provided by

Licensor 2. Power : As provided by Licensor for ISBL , OSBL is as per in-house estimation. 3. Plant Air : Requirement is only for Hose station it is assumed that total no. of

hose stations operating simultaneously is same as in original complex design as new units will be located in brownfield area..

4. Instrument Air: Estimated 5. Nitrogen: Estimated based on Blanketing requirement for Tanks and Surge

Drum. 6. Chilled Water : As per Licensor data

Option 1 : Only Styrene Recovery Facility in PNCP Complex Utilities Requirement is indicated as the Sum of Styrene recovery & Offsite facility.

Table 6.5.1.2: Total Utility Requirement : Option-1

Utility UOM Design Case Option-1

Check Case Option-1

Normal Design Normal Design

HP Steam Tons/hr 0.0 0.0 0.0 0.0

MP Steam Tons/hr 20.5 23.6 25.6 29.5

LP Steam Tons/hr 8.6 9.9 10.8 12.4

Cooling Water m3/hr 683 785 853 981

Chilled Water m3/hr 6.3 7.2 7.9 9.1

Power kWh 318 365 398 458

BFW m3/hr 0.5 0.6 0.6 0.7

Nitrogen Nm3/hr 50 57 50 57

Instrument Air Nm3/hr 270 311 270 311

Option 2 : Integrated Styrene & Toluene & Xylene Recovery , Utilities Requirement is listed in table below which is the Sum of Styrene recovery,



Rev. No. 0

Page 71 of 96




Toluene Xylene Extraction & Offsite facility.

Table 6.5.1.3: Total Utility Requirement : Option-2

Utility UOM Design Case Option-2

Check Case Option-2

Normal Design Normal Design

HP steam t/hr 6.2 7.1 7.8 8.9

MP Steam t/hr 53.5 61.5 66.9 76.9

LP Steam t/hr 8.6 9.9 10.8 12.4

Cooling Water m3/hr 768 883 960 1103

Chilled Water m3/hr 6.3 7.2 7.9 9.1

Power kWh 648 745 809 931

BFW m3/hr 0.5 0.6 0.6 0.7

Nitrogen Nm3/hr 220 253 220 253

Instrument Air Nm3/hr 470 541 470 541



Rev. No. 0

Page 72 of 96




6.6 Offsites Description

6.6.1 Flare System

The existing flare system shall be used for safe disposal of combustible gases which are relieved from the new proposed units during start-up, shut-down, normal operation or in case of an emergency. The flare load data for different failure cases for the new facilities are not available at this stage. The existing NCU flare system has a very high design load which should be adequate to accommodate the new unit requirement.

6.6.2 Offsite Facilities

A detailed Study was carried out on the additional Storage Requirements as part of the new facilities. The Offsite Facilities required is summarized as follows :

Sl.No.

Product Location No. Of Tanks

Days Storage

Tank Volume in m3

1 Styrene Day Tanks

Within NCU B/L

2 2 2 x 110

2 Styrene Product Tank

Offsite area

1 7 700

3 Toluene Product Tanks

Offsite area

2 10 2 x 2800

4 Mixed Xylene Product Tanks

Offsite area

2 15 2 x 2300

The storage facilities were estimated based on the following assumptions : 1. Styrene Tanks are as specified/recommended by the Licensor

2. No feed storage is considered for Styrene Recovery unit. In case of Styrene unit

shutdown, present routing of total Heavy of pygas will be considered.

3. Product Styrene is to be routed to SBR unit. One Product Styrene Tank with Seven days storage, is considered as per the design Basis.

4. All tank capacities indicated are based on 1000 KTPA NCU Capacity and on the basis of no. of days agreed in the design Basis as there is marginal increase between two.

5. For Xylene and toluene , two tanks have been considered. One in receiving and other will be in dispatch mode.

6. In addition Styrene storage refrigeration facility and Toluene loading vapor recovery system is also be considered in the study.



Rev. No. 0

Page 73 of 96




Pumping facilities required as part of the New facility in the Project is as detailed below :

Sl.No. Product Stream Flow rate in m3/hr No. Of Pumps

1 Styrene Transfer Pumps 36 1 + 1

2 Styrene Circulation Pumps

5 1 + 1

3 Toluene Transfer Pumps 17 1 + 1

4 Mixed Xylenes Pumps 10 1 + 1

Additional Equipments required in the Product Storage area are.

Chiller system & Styrene cooler Chiller Capacity considered : 16.5 Tons of refrigeration, requirement : 1 operating + 1 standby Medium: Ethylene Glycol Chilled water Temperature range : Inlet : 5 deg C, outlet : 10 deg C

Vapor Recovery System with New loading facilities for Toluene has been considered for Cost Estimate purpose.

6.6.3 OSBL Lines

OSBL pipelines will be required to be made for feed, product and intermediate products streams connecting new Process units / offsite area and PX/PTA area which are listed below.

1. HPG feed to styrene unit

2, C7- C8 raffinate to RPG unit

3. Styrene Product to Storage

4. Feed Styrene to SBR unit

5. C7-C8 Raffinate feed to Toluene unit

6. Toluene Pdt to storage Tanks

7. toluene Feed to PX/PTA refinery unit

8. Mixed Xylene Pdt to Offsite Tanks

9. Mixed Xylene to Existing Loading Area

10. C7-C8 Raffilnate to Refinery Gasoline Pool

11. C7- C8 Raffinate to NCU unit as feed.

As utilities / flare / effluents will be connected to existing facilities, those are considered to be within ISBL only. Refer Annexure-IV for suggested hookup drawing.

6.6.4 Fire Fighting Facilities

Since all new process equipments are to be located in the existing NCU B/L. The existing fire fighting system for NCU is considered as adequate.



Rev. No. 0

Page 74 of 96




Chapter 7.0 Environmental Considerations



Rev. No. 0

Page 75 of 96




7.0 Environmental Considerations

7.1 Effluent Details

The effluent summary provided below are as given by the Licensor of Styrene and Toluene/Xylene Recovery Units

7.1.1 Solid Effluents

Table 4.2.10.1: Solid Effluents

S. No.

Unit Name Source Quantity (Kg/hr)

Quality Disposition Frequency

1.

Styrene Recovery

PA Selective Hydrogenation Reactors

Note-1 5 years Note-1 Note-1,2

2. Xylene/ Toluene recovery

Solvent regeneration

0.3 m3/Month

Polymerize viscous material

Incineration (Note 3)

3-24 month

Note: 1. Spent Catalyst from PA Selective Hydrogenation Reactors after every 5 years will be

spent. The precious metal needs to be recovered after sending to manufacturer.

2. Solid Effluent ( selective hydrogenation spent catalyst ) disposal will be done in the same method used for the PGHU catalyst in the existing PNCP complex as a landfill after precious metal recovery.

3. Incinerable material ( ~ 80 kg/month) generated in the unit can have to incinerated.

Possibility of using the existing facility in MEG Plant to be checked during execution stage. Alternatively in case incineration is considered outside complex, additional drum filling and drum storage facility to be considered with in the complex.

7.1.2 Liquid Effluents

Table 4.2.10.2: Liquid Effluents

S. No.

Unit Name Source Qty (Kg/hr)


1.

Styrene Recovery

Water purge from surge drum Solvent regeneration dump out

200 20Kg/ week

Note-1 Note-2

ETP Fuel oil or waste incineration

Intermittent Weekly

2.

Xylene/ Toluene recovery

Water surge drum (D-203)

0.8-1 m3/hr Water having trace of HC and solvent

Waste water treatment

1 week



Rev. No. 0

Page 76 of 96




3.


Ejector condensate drum in vacuum system

0.5-1.5 m3/hr

Water having trace of HC (3000-4000 ppm Toluene)

Waste water collection drum

Normally no flow

Note -1

Composition Techtiv-200 solvent 5wppm

Styrene & C8 Aromatics 0.08%

Water Balance

This material shall be accommodated in the existing ETP.

Note-2 Composition Wt% Polymerized viscous material (35% sulfur; 65% aromatic hydrocarbon)

20-30%

Styrene dimer/trimer 35-45%

Styrene polymer 30-40%

Possibility of blending this material into fuel oil needs to be reviewed by IOCL. Otherwise incineration methodology/location is to be identified.

7.1.3 Gaseous effluent

Table 4.2.10.3: Gaseous Effluents

Sl. No.

Unit Name Source Qty (Kg/hr)


1. Styrene Recovery

Reactor regeneration off gas

Flare for 3 days duration in 1-2 years

2.


Ejector condensate drum in vacuum system

Subjected to SRC system tightness, disposition to atmosphere. For upset, system interlock will activate to avoid HC emission.

7.2 Flare Load

Presently flare load is not available. However, the flare Load from these additional units are expected to be low for cumulative failure cases (general power failure or cooling water failure). Considering NCU hot flare design to be very high, it was decided with IOCL that new flare header will be connected to existing NCU hot flare.



Rev. No. 0

Page 77 of 96




7.3 Effluent Treatment Plant

As the liquid effluents are intermittent and small in quantity with respect to present capacity of ETP for PNCP complex. There will be no separate Wastewater treatment plant for new facilities. The effluents from the STYRENE recovery unit and Toluene/ Xylene extraction unit is suggested to be accommodated in the existing facilities.



Rev. No. 0

Page 78 of 96




Chapter 8.0 Project Implementation and Schedule



Rev. No. 0

Page 79 of 96




8.0 Project Implementation and Schedule

For project implementation and schedule the following assumption and stipulation has been considered, (For bar chart, please refer annexure –I)

Only Styrene recovery unit (Option-1)

1. Zero Date of the Project is considered as Award of Contract to the Consultant.

2. Mode of Project executions has been considered on Conventional Basis (EPCM).

3. Schedule has been prepared considering that the Utilities (e.g., Power, Raw

water, DM water, Cooling Water, Steam, Nitrogen, Instrument Air, Service water, Fire water, ETP, Flare etc.) are available as per Schedule requirement from existing refinery facilities.

4. The schedule has been prepared covering the following units / facilities:

(a). Only Styrene Recovery unit including Feed preparation unit.

5. All Enabling works / infrastructure facilities (graded site, approach roads, construction water, construction power, open storage yard, construction site office, Material Handling, Fabrication yard etc.) is considered to be available suitably in advance in order to meet the construction requirement.

6. Provision of New Control room & Sub‐ station is not considered. If required then

shall be executed through Civil/ Structural contractor

7. Piling is considered.

8. 3 nos. Piping MTO’s have been considered.

9. Tankage works considered under Mechanical Works contract.

10. Procurement of Structural Steel, Cement, Cable trays, Cable ducts, Earthing materials and other consumables considered in contractor scope.

11. Standard Ordering & Tendering Cycles considered for developing the schedule.

12. All Statutory approval to establish the units considered to be in scope of IOCL

and shall be available progressively before commissioning as per requirement.

13. Graded site free from encumbrances to be handed over to carry out construction activities. Any dismantling of existing facilities at proposed location shall be in scope of IOCL.

14. Effect of Monsoon shall depend on the date of Award of Contract (Zero date),

and will govern the construction work (Monsoon from March to September each year). Minimum 2 monsoon period will fall during the entire Project duration.

15. Since work has to be executed in existing Refinery, necessary barricading shall

be done by the respective agencies during pre‐ shutdown period, while working in the operational area. Work permits assumed to be available to carry out construction activities.



Rev. No. 0

Page 80 of 96




16. Modification of existing systems (if any) not considered.

17. Shutdown is assumed to be available as and when required w.r.t. schedule requirement for hook‐ up with existing facilities / Utilities.

18. Durations of Pre-commissioning & Commissioning assistance is tentative and will

be drawn during project execution period.

Styrene + TX Recovery Unit (OPTION 2)

1. Zero Date of the Project is considered as Award of Contract to Consultant.

2. Mode of Project execution has been considered on Conventional Basis (EPCM).

3. Schedule has been prepared considering that the Utilities (e.g., Power, Raw water, DM water, Cooling Water, Steam, Nitrogen, Instrument Air, Service water, Fire water, ETP, Flare etc.) are available as per

4. The schedule has been prepared covering the following units / facilities:

(a). Integrated Styrene, Mixed Xylenes & Toluene Recovery configuration

5. All Enabling works / infrastructure facilities (graded site, approach roads, construction water, construction power, open storage yard, construction site office, Material Handling, Fabrication yard etc.) is considered to

6. Provision of New Control room & Sub‐ station is not considered. If required then

shall be executed through Civil/ Structural contractor

7. Piling is considered.

8. 3 nos. Piping MTO’s have been considered.

9. Procurement of Structural Steel, Cement, Cable trays, Cable ducts, Earthing materials and other consumables considered in contractor scope.

10. Standard Ordering & Tendering Cycles considered for developing the schedule.

11. All Statutory approval to establish the units considered to be in scope of IOCL

and shall be available progressively before commissioning as per requirement.

12. Graded site free from encumbrances to be handed over to carry out construction activities. Any dismantling of existing facilities at proposed location shall be in scope of IOCL.

13. Effect of Monsoon shall depend on the date of Award of Contract (Zero date),

and will govern the construction work (Monsoon from March to September each year). Minimum 2 monsoon period will fall.

14. Since work has to be executed in existing Refinery, necessary barricading shall

be done by the respective agencies during pre-shutdown period, while working in the operational area. Work permits assumed to be

15. Modification of existing systems (if any) not considered.

16. Shutdown is assumed to be available as and when required w.r.t. schedule



Rev. No. 0

Page 81 of 96




requirement for hook-up with existing facilities / Utilities.

17. Durations of Pre-commissioning & Commissioning assistance is tentative and will be drawn during project execution period.



Rev. No. 0

Page 82 of 96




Chapter 9.0 Project Cost Estimates



Rev. No. 0

Page 83 of 96




9.0 Project Cost Estimates

9.1 Introduction

Indian Oil Corporation Limited (IOCL) is exploring the feasibility of recovery of Styrene,

Mixed Xylene & Toluene from Heavy Pyrolysis Gasoline coming out from their existing

Panipat Naphtha Cracker Complex. Accordingly they have awarded EIL a job of

preparing Feasibility Report (FR) for Styrene, Mixed Xylene & Toluene recovery unit and

associated facilities.

The objective of the FR is to prepare cost estimate and carry out profitability analysis for

setting up Styrene Recovery Unit and Mixed Xylene / Toluene Recovery Unit at Panipat,

Haryana.

9.2 Scope

The scope of the project covers the following Process units / Utilities & Offsite facilities of

respective options:

S.N. Unit Description

Capacity

Design Case

Option - 1

Design Case

Option-2

1 Styrene Recovery Unit 20 KTA 20 KTA

2 Xylene / Toluene Recovery

Unit - 220 KTA

3 Utilities & Offsite Associated U&O Associated U&O

9.3 Reference Document

Reviewed Equipment lists of Licensor & Other input from Process

9.4 Project Cost

Capital cost estimate for the identified scope works has been worked and is tabulated below :

S.N. Description Fc

(Rs. Crores)

Ic

(Rs. Crores)

Total

(Rs. Crores)

1 Design Case – Option1 50.84 139.72 190.56

2 Design Case – Option2 82.67 246.39 329.06



Rev. No. 0

Page 84 of 96




Validity of Cost estimate is as of Jun-2012 price basis and estimated cost is for conventional mode of execution.

This Capital cost estimate shall be read along with Key assumptions and Exclusions listed at Para 9.5 & 9.6.

9.5 Key Assumptions

The basic assumptions made for working out the capital cost estimate are as under:

Cost Estimate is for a grass roots/green field site only.

Cost estimate is valid as of Jun-2012 price basis.

No provision has been made for any future escalation

No provision has been made for any exchange rate variation.

It has been assumed that the total project / all units would be implemented on conventional mode.

Consultancy services cost is added as lump-sum based on in-house information / input.

All costs are reflected in INR and all foreign costs have been converted into equivalent INR using exchange rate of 1USD=Rs. 48.00

9.6 Exclusions

Following costs have been excluded from the Project cost estimate:

Forward escalation

Exchange rate variation

Land

Piling Works – Not required based on on-going jobs at same location

Effluent Treatment System

Railway siding

Removal of unseen / unidentified underground obstructions

Maintenance and Workshop equipment

Any cost towards dismantling, removal of existing facilities / obstructions

Rehabilitation cost

Cost towards statutory clearances

9.7 Estimation Methodology

As indicated in para 4.0, the estimated project cost for the identified scope of Design Case and technical details works out to `190.56 Crores with a foreign component of ` 50.84 crores for Option-1 & `329.06 Crores with a foreign component of ` 82.67 crores for Option-2

Cost estimate is based on cost information available from EIL’s current in-house cost data and Engineering inputs for cost estimation purpose. In-house cost data has been analyzed and adopted for estimation after incorporating specific project conditions. Cost data has been updated to prevailing price level using relevant economic indices.



Rev. No. 0

Page 85 of 96




Estimated costs generated have been benchmarked against past projects of similar nature and location.

These Cost estimates are subject to identified scope of work and engineering inputs / technical information, assumptions and exclusions stated herein.

The accuracy of these estimates is targeted at +30% based on the methodology used.

9.7.1 Process Units

The cost estimate for Process Units has been prepared based on equipment list provided by Licensor and reviewed by Process department for the required scope of work. Cost provision for Supply of Bulk Materials such as Piping, Electrical & Instrumentation works and Site works e.g. Civil & Structural Works, Erection works, Insulation & Painting has been made on factor basis as per in-house norms.

Cost provision for Proprietary supply of Licensor i.e. M/s GTC and some special equipment has been considered based on information provided.

The cost estimates for Process units are based on their capacity and battery limit scope only.

9.7.2 Utilities & Offsites

The estimated cost for various Utilities & Offsite facilities consist of following major systems/facilities:

Storages

Associated Pumps

Refrigeration Package

Vapour Recovery System

No provision has been made for Utilities system and the same has been considered from the existing facilities. Only hook-up / connection lines to the existing header are included in cost estimate.

The cost has been estimated based on in-house engineering information and recent in-house cost data available for similar facilities implemented in other projects. A factored approach has been adopted to estimate the cost provision for piping, electrical, instrumentation and spares. Lump-sum cost provision has been made for Fire protection system. No provision has been kept for any modification for existing DCS and Flare system.

9.7.3 Scope of Factors

The factors used under clause no. 9.7.1 & 9.7.2 are for the following items:

Civil and structural items for foundations, technical structures, pipe-racks materials and labour

Plant buildings such as compressor house, control room etc.

Installation of Equipment



Rev. No. 0

Page 86 of 96




Ladders & Platforms

Piping materials supply and installation.

Electrical & Instrumentation materials supply and installation.

Insulation, Painting and fireproofing materials supply and installation.

The factors used under clause no.9.7.1 & 9.7.2 exclude the following items:

Site preparation & development such as pavements, drainage, leveling, earth work, filling, boundary wall, etc.

Roads & Non-plant buildings such as administration & workshop building etc.

Piling works

High voltage electrical equipment and switch yard etc.

Any unusual construction requirements

9.7.4 Catalysts & Chemicals

Cost provision towards 1st Fill of Catalyst & Chemical has made based on quantities required and respective unit rates provided.

9.7.5 Indirect Costs, Exchange Rates and Statutory taxes/duties

9.7.5.1 Indirect Costs, Exchange Rates

The cost estimate is based on following Exchange Rates & Indirect costs:

Exchange Rate 1 US$=Rs.55.00, 1 Euro=Rs.68.00

Ocean Freight 5.0% of FOB cost of imported equipment

Port Handling 2.0% of FOB cost of imported equipment

Inland freight 5% of FOB cost of imported equipment and ex-works cost of indigenously sourced equipment

Insurance 1% of total cost

Provision for ocean freight is for supplies by marine transportation / ships only. No provision has been kept for any special transportation means such as Air freighting or usages of barges.

9.7.5.2 Statutory Taxes and Duties

Provision for statutory taxes & duties has been made as under:

Custom Duty 22.85% of CIF cost of imported equipment (5% Basic Customs Duty + 12% CVD+ 3% Education Cess and 4% SAD).

Excise Duty 12.36% of ex-works cost of indigenously sourced equipment.

Central Sales Tax 2% of ex-works cost of indigenously sourced equipment including excise duty.

VAT / Works Contract Tax 4% of subcontracted works

State Entry Tax Nil

Service Tax on 12.36 (12% Service Tax + 3% Education Cess)



Rev. No. 0

Page 87 of 96




Engineering

Service Tax on Works Contract

4.944% (12% Service Tax on 40% Value + 3% Education Cess)

Cost estimate does not consider any cenvatable benefits, if available.

9.7.6 Royalty, Know-How, Process Design / Basic Engineering Fees

Provision for Royalty, Know-how, Process Design and Basic Engineering has been made based on licensor’s information / in-house data. Cost includes provision for withholding tax and service tax.

9.7.7 Project Management, Detailed Engineering, Procurement Services & Construction Supervision

Cost provision has been kept towards the services of project management, detailed engineering, procurement services & construction supervision assistance based on in-house information. Service tax @ 10.3% has also been considered. This fee is indicative in nature. The actual fee chargeable shall be obtained from EPCM consultant based on actual scope of work to be executed.

9.7.8 Land and Site Development

Cost provision for Site development i.e. mainly for Site grading, Barricading & Pavement has been made based on layout area and assumed that there will be no major cutting of earth involved. Boundary wall has not been considered. Cost of Land & Piling has been excluded from cost estimate.

9.7.9 Roads & Buildings

Cost provision for 6 m wide and for length of 100 m has been considered in the cost estimate. Cost for any Building has been excluded from the cost estimate since existing facilities will be used.

9.7.10 Effluent Treatment Plant/ Water Supply & Public Health

Excluded from the cost estimate as existing facilities is planned to be used.

9.7.11 Office equipment & furniture

Lump sum provision of Rs. 20 Lakhs has been made for Office Equipment & Furniture.

9.7.11 Railway Siding

Not envisaged

9.7.12 Construction Site Requirement



Rev. No. 0

Page 88 of 96




A lump-sum cost provision has been made for items such as Construction Power, Construction Water, Warehouse and Construction equipment etc.

9.7.13 Township

Cost provision has been made for building of 20 flats of 1000 sq feet area each. Land for the same will be provided by Client free of cost.

9.7.14 Owners Construction Period Expenses

A lump sum cost provision for owner’s construction period expenses has been made as per in-house norms for items such as project management, salaries & wages, environment clearances, feasibility reports, fund raising, recruitment, training requirement, legal expenses, office and vehicles hire / rentals / maintenance, stationary, postage, travel etc. during project construction / execution period

9.7.15 Start-up & Commissioning

A lump-sum cost provision has been made for chemicals & consumables, vendor servicemen, technician & operators required during start-up and commissioning period.

9.7.16 Contingency

Provision for contingency has been made @ 5% of capital cost excluding Margin Money as advised by IOCL and Interest during Construction (IDC). This provision has been kept to take care of inadequacies in estimate basis definitions (including design and execution) and inadequacies in estimating methods and data elements.

9.7.17 Working Capital Margin

Working capital has not been considered as informed by Client.

9.7.18 Interest during construction

Interest during construction required for the project has been worked out on the following

basis:

Debt - Equity ratio : 60:40

Rate of interest : 11.8%

Expenditure pattern : Concurrent

Construction period : 3 years

Phasing of Capital Expenditure : 1st yr- 15%, 2nd Yr-50%, 3rd Yr-35%

Based on the above assumptions and exclusions, Project cost Summary for Design Case – Option1 & Option2 are enclosed as Annexure-I.

9.7.19 Financial Analysis

Excluded from scope of Project.



Rev. No. 0

Page 89 of 96




9.7.20 Enclosures

Enclosure – I:

Design Case – Option1 & Option2:

Project Cost Summary – 4 sheets

The estimated capex for the check case (based on prorate factor of unit capacities) is attached in Annexure-II.



Rev. No. 0

Page 90 of 96




Enclosure – I



Rev. No. 0

Page 91 of 96






Rev. No. 0

Page 92 of 96






Rev. No. 0

Page 93 of 96




PROJECT : Styrene Recovery Project, IOCL

NO. D E S C R I P T I O N ALL COSTS ARE IN RS. LAKHS

JOB NO. A202

Fc Ic Sc. TOTAL CLIENT IOCL

1 EQUIPMENTS/SYSTEMS LOCATION PANIPAT

1.1 COLUMNS WITH INTERNALS 10 24 10 90 3 43 24 57 CAPACITY 20 KTA

1.2 VESSELS 1 20 29 1 49 UNIT Styrene Recovery Unit

1.3 REACTORS 1 44 1 44 Licensor GTC

1.4 HEAT EXCHANGERS 5 90 5 90 Bidding Doc.

1.5 AIR COOLERS 1 55 1 55

1.6 PUMPS & DRIVES 2 42 2 42

1.7 COMPRESSOR - Not Applicable

1.8 HEATERS - Not Applicable TYPE OF ESTIMATE

1.9 PACKAGES & MISCELLANEOUS 3 74 1 28 5 02

SUB-TOTAL (1)... 13 98 24 69 3 72 42 39 EXECUTION METHODOLOGY

2 BULK MATERIALS

2.1 PIPING 1 48 5 94 7 42

2.2 ELECTRICAL 4 24 4 24

2.3 INSTRUMENTATION 1 59 4 77 6 36 ESTIMATE VALIDITY

Jun-12

SUB-TOTAL (2)... 3 07 14 94 18 02

3 SPARES 48 1 43 1 91

4.1 CATALYSTS - Excluded EXCHANGE RATES

4.2 CHEMICALS & ADDITIVES 1 US $ = INR 55.00

SUB-TOTAL OF P&Mc (1 to 4) 17 53 41 06 3 72 62 32 1 Euro = INR 68.00

5 ERECTION Customs Duty 22.85%

5.1 MECHANICAL 6 83 6 83 Excise Duty 12.36%

5.2 ELECTRICAL 85 85 Sales Tax 2.00%

5.3 INSTRUMENTATION 1 27 1 27 WCT 4.00%

SUB-TOTAL (5) 8 95 8 95 Service Tax 12.36%

Service Tax on S/C 4.94%

6 CIVIL & STRUCTURAL WORKS 9 06 9 06

7 BUILDINGS

8 PILING

9

INSULATION, PAINTING, FIRE

PROOFING & CHEMICAL

CLEANING

1 49 1 49

SUB-TOTAL (1 to 9)... 17 53 41 06 23 23 81 83 PROJECT MANAGER

Ms Jayati Ghosh

10 INDIRECT COSTS

10.1 OCEAN FREIGHT 88 88

10.2 CUSTOMS DUTY 4 21 4 21 Manoj / Shiv Kr

10.3 EXCISE DUTY 5 08 5 08

10.4 SALES TAX 92 92 Prachi Gupta

10.5 PORT HANDLING 35 35

10.6 INLAND TRANSPORTATION 2 93 2 93 Anil Kumar

10.7 STATE ENTRY TAX

10.8 VAT/ WCT/ SERVICE TAX 2 08 2 08 S U M M A R Y

10.9 INSURANCE 98 98 Process Unit (Battery Limit)

SUB-TOTAL (10)... 88 14 47 2 08 17 42

SUB-TOTAL (1 TO 10)... 18 41 55 53 25 31 99 25 DOCUMENT NO. A202-FR-6842-0001

11 Exclusions : REVISION NO. 1

Custom Duty DATE : 17-Aug-2012

Excise Duty

Sales Tax

State Entry Tax

Insurance

Service Tax on WCT

SUB-TOTAL (11)...

T O T A L C O S T ... 18 41 55 53 25 31 99 25 Page No. 2 of 2

Format no. 5-6842-1000-F3 Rev.4

FILE NAME

D:\Manoj\A202_Styrene Recovery

Unit_IOCL\Estimate_Rev-E_Final

Report_R1\[A202_Styrene

Recovery Unit.xls]Summ

COST ENGINEERING DEPARTMENT

STYRENE RECOVERY UNIT ( Licensor : M/s GTC)

Feasibility Study

Conventional

PREPARED BY

REVIEWED BY

APPROVED BY



Rev. No. 0

Page 94 of 96




PROJECT : Styrene Recovery Project, IOCL

NO. D E S C R I P T I O N ALL COSTS ARE IN RS. LAKHS

JOB NO. A202

Fc Ic Sc. TOTAL CLIENT IOCL

1 EQUIPMENTS/SYSTEMS LOCATION PANIPAT

1.1 COLUMNS WITH INTERNALS 1 60 7 11 1 38 10 09 CAPACITY 220 KTA

1.2 VESSELS 40 17 57 UNIT Xylene & Toluene Recovery

1.3 REACTORS Licensor GTC

1.4 HEAT EXCHANGERS 4 97 4 97 Bidding Doc.

1.5 AIR COOLERS 2 90 2 90

1.6 PUMPS & DRIVES 2 46 2 46

1.7 COMPRESSOR - Not Applicable

1.8 HEATERS - Not Applicable TYPE OF ESTIMATE

1.9 PACKAGES & MISCELLANEOUS

SUB-TOTAL (1)... 1 60 17 84 1 55 20 98 EXECUTION METHODOLOGY

2 BULK MATERIALS

2.1 PIPING 73 2 94 3 67

2.2 ELECTRICAL 2 10 2 10

2.3 INSTRUMENTATION 79 2 36 3 15 ESTIMATE VALIDITY

Jun-12

SUB-TOTAL (2)... 1 52 7 40 8 92

3 SPARES 10 1 01 1 11

4.1 CATALYSTS EXCHANGE RATES

4.2 CHEMICALS & ADDITIVES 1 US $ = INR 55.00

SUB-TOTAL OF P&Mc (1 to 4) 3 22 26 24 1 55 31 01 1 Euro = INR 68.00

5 ERECTION Customs Duty 22.85%

5.1 MECHANICAL 3 41 3 41 Excise Duty 12.36%

5.2 ELECTRICAL 42 42 Sales Tax 2.00%

5.3 INSTRUMENTATION 63 63 WCT 4.00%

SUB-TOTAL (5) 4 46 4 46 Service Tax 12.36%

Service Tax on S/C 4.94%

6 CIVIL & STRUCTURAL WORKS 4 48 4 48

7 BUILDINGS

8 PILING

9

INSULATION, PAINTING, FIRE

PROOFING & CHEMICAL

CLEANING

74 74

SUB-TOTAL (1 to 9)... 3 22 26 24 11 23 40 69 PROJECT MANAGER

Ms Jayati Ghosh

10 INDIRECT COSTS

10.1 OCEAN FREIGHT 16 16

10.2 CUSTOMS DUTY 77 77 Manoj / Shiv Kr

10.3 EXCISE DUTY 3 24 3 24

10.4 SALES TAX 59 59 Prachi Gupta

10.5 PORT HANDLING 6 6

10.6 INLAND TRANSPORTATION 1 47 1 47 Anil Kumar

10.7 STATE ENTRY TAX

10.8 VAT/ WCT/ SERVICE TAX 1 00 1 00 S U M M A R Y

10.9 INSURANCE 48 48 Process Unit (Battery Limit)

SUB-TOTAL (10)... 16 6 62 1 00 7 79

SUB-TOTAL (1 TO 10)... 3 38 32 86 12 24 48 48 DOCUMENT NO. A202-FR-6842-0001

11 Exclusions : REVISION NO. 1

Custom Duty DATE : 17-Aug-2012

Excise Duty

Sales Tax

State Entry Tax

Insurance

Service Tax on WCT

SUB-TOTAL (11)...

T O T A L C O S T ... 3 38 32 86 12 24 48 48 Page No. 2 of 2

Format no. 5-6842-1000-F3 Rev.4

FILE NAME

D:\Manoj\A202_Styrene Recovery

Unit_IOCL\Estimate_Rev-E_Final

Report_R1\[A202_Styrene Recovery

Unit.xls]Summ


Xylene & Toluene Recovery Unit ( Licensor : M/s GTC)

Feasibility

Conventional

PREPARED BY

REVIEWED BY

APPROVED BY



Rev. No. 0

Page 95 of 96




Chapter 10.0 Annexure



Rev. No. 0

Page 96 of 96




10.0 Annexure Annexure-I Project Implementation and Schedule Annexure-II Estimated Project Cost for Check Case Annexure-III Equipment List Annexure-IV Hook-ups Annexure-V Overall Block Flow Diagram Annexure-VI Schematic Process Flow Diagrams Annexure-VII Unit Layout Annexure-VIII Overall Plot Plan



Rev. No. 0

Page 1 of 3




Annexure- I Project Implementation and Schedule

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

1.0 PROJECT START DATE / ZERO DATE 0

2.0 KICK OFF MEETING/ FINALIZATION OF PHILOSOPHY TO BE READ ALONG WITH STIPULATION ANNEXED AS ANNEXURE‐I

3.0 LICENSOR FINALIZATION/ PACKAGE

3.1 TENDER DOCUMENT PREPARATION/ FINALIZATION 1.25 M

3.2 SELECTION OF LICENSOR 4 M

3.3 LICENSOR PROCESS PACKAGE 4 M

3.4 DATA SHEETS FOR CRITICAL EQUIPMENTS

4.0 PROCESS

4.1 RECEIPT OF PROCESS PACKAGE FROM LICENSOR

4.3 RESIDUAL BASIC ENGINEERING FOR LICENCED UNITS

4.2 PROCESS DESIGN PACKAGE OF UTILITIES & OFFSITE

5.0 DETAILED ENGINEERING

5.1 GENERAL CIVIL

5.2 PIPING

5.3 CIVIL/ STRUCTURAL

5.4 ELECTRICAL/ INSTRUMENTATION

6.0 PROCUREMENT

6.1 COLUMNS (9 NOS.) 10 M ‐ 12 M

6.2 REACTORS (2 NOS.) 14 M

6.3 PUMPS (Unit:52 + Offsite: 4 NOS.) 8 M ‐ 12 M

6.4 HEAT EXCHANGERS (30 NOS.) 8 M ‐ 10 M

6.5 AIR COOLERS (3 NOS.) 8 M

6.6 VESSELS / TANKS (19/2 NOS.) 8‐12 M

6 7 VACUM PACKAGES (1 NO ) 10 M

SL. NO.

ACTIVITY DESCRIPTION DUR.DURATION IN MONTHS

30%Model

R

R

R R

R

60%Model

90%Model

1stMTO

Prilim.Plot Plan

Plot Plan for Engg.

2nd MTO

Final MTO

Eqpt. Layout

R R

R R

R

Utility P&IDs

HAZOP

R

Process P&IDs ‐Issued for Engg.

6.7 VACUM PACKAGES (1 NO.) 10 M

6.8 PIPING (BULK MATERIAL)

6.9 DCS (PROCUREMENT & INSTALLATION) 8 M

6.1 ELECTRICAL ITEMS 6‐10 M

6.11 INSTRUMENTATION ITEMS 6‐10 M

7.0 TENDERING / CONSTRUCTION

7.1 PILING WORKS 4 M

7.2 CIVIL/ STRUCTURAL & UG PIPING WORKS 10 M

7.3 MECHANICAL WORKS 12 M

7.4 ELECTRICAL WORKS 10 M

7.5 INSTRUMENTATION WORKS 10 M

8.0 PRE ‐COMM'G / COMM'G ASSISTANCE

8.1 AVAILABILITY OF UTILITIES

8.2 PRE ‐COMM'G / COMM'G

LEDENDS MILESTONE Tender on sale Material Receipt at site ‐Part Execution time for activity

ISSUE ENQUIRY Issue FOA/ Award Material Receipt at site ‐Complete

CLIENT: APPV BYM/s IOCL

DOCUMENT NO.

PURPOSE

ISSUED FOR FEASIBILITY REPORT

A202‐RP‐2744‐0001‐0DATEREV PREP BY

OVERALL PROJECT SCHEDULE(PROPOSED)

REV BY

STYRENE RECOVERY UNIT WITH FEED PREPARATION UNIT AT PNCP COMPLEX, PANIPAT (OPTION 1 ) 15.02.120 SPS

PROJECT:SK/ TK JG

R1

R

R

T

T

T

T

T

MECHANICAL COMPLETION

COMMISSIONING

R

R

R

R

T

R

R2

R3

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

1.0 PROJECT START DATE / ZERO DATE 0

2.0 KICK OFF MEETING/ FINALIZATION OF PHILOSOPHY TO BE READ ALONG WITH STIPULATION ANNEXED AS ANNEXURE‐I

3.0 LICENSOR FINALIZATION/ PACKAGE

3.1 TENDER DOCUMENT PREPARATION/ FINALIZATION 1.25 M

3.2 SELECTION OF LICENSOR 4 M

3.3 LICENSOR PROCESS PACKAGE 4 M

3.4 DATA SHEETS FOR CRITICAL EQUIPMENTS

4.0 PROCESS

4.1RECEIPT OF PROCESS PACKAGE FROM LICENSOR FOR INTEGRATED STYRENE, MIXED XYLENE AND TOULENE RECOVERY

4.2 RESIDUAL BASIC ENGINEERING FOR LICENCED UNITS‐STYRENE

4.3 RESIDUAL BASIC ENGINEERING FOR LICENCED UNITS‐TOULENE

4.4 PROCESS DESIGN PACKAGE OF UTILITIES & OFFSITE

5.0 DETAILED ENGINEERING

5.1 GENERAL CIVIL

5.2 PIPING

5.3 CIVIL/ STRUCTURAL

5.4 ELECTRICAL/ INSTRUMENTATION

6.0 PROCUREMENT

6.01 COLUMNS (9 + 6 NOS.) 10 M ‐ 12 M

6.02 REACTORS (2 NOS.) 14 M

6.03 PUMPS (Units: 52 + 31, Offsites: 4 + 8 NOS.) 8 M ‐ 12 M

6.04 HEAT EXCHANGERS (30 + 22 NOS.) 8 M ‐ 10 M

6.05 AIR COOLERS (3 + 9 NOS.) 8 M

6.06 VESSELS / TANKS (19/2 + 8/2 NOS.) 8‐12 M

SL. NO.

ACTIVITY DESCRIPTION DUR.DURATION IN MONTHS

30%Model

R

R

R R

R

60%Model

90%Model

1stMTO

Prilim.Plot Plan Plot Plan

for Engg.

2nd MTO

Final MTO

Eqpt. LayoutUnit 1

R R

R R

Utility P&IDs

HAZOP

R

Eqpt. Layout Unit 2

HAZOP

PROCESS P&IDs ‐ ISSUED FOR ENGINEERING

PROCESS P&IDs ‐ ISSUED FOR ENGINEERING

/ ( / / )

6.07 VACUM PACKAGES (1 NO.) 10 M

6.08 CHILLER SYSTEM (1 NO.) 12 M

6.09 VAPOUR RECOVERY SYSTEM (1 NO.) 12 M

6.1 PIPING (BULK MATERIAL)

6.11 DCS (PROCUREMENT & INSTALLATION) 8 M

6.12 ELECTRICAL ITEMS 6‐10 M

6.13 INSTRUMENTATION ITEMS 6‐10 M

7.0 TENDERING / CONSTRUCTION

7.1 PILING WORKS 5 M

7.2 CIVIL/ STRUCTURAL & UG PIPING WORKS 12 M

7.3 MECHANICAL WORKS 14 M

7.4 ELECTRICAL WORKS 12 M

7.5 INSTRUMENTATION WORKS 12 M

7.6 TANKAGES WORK 14 M

8.0 PRE ‐COMM'G / COMM'G ASSISTANCE

8.1 AVAILABILITY OF UTILITIES

8.2 PRE ‐COMM'G / COMM'G

LEDENDS MILESTONE Tender on sale Material Receipt at site ‐Part Execution time for activity

ISSUE ENQUIRY Issue FOA/ Award Material Receipt at site ‐Complete

CLIENT:

PROJECT:INTEGRATED STYRENE, MIXED XYLENES & TOLUENE RECOVERY UNIT AT PNCP COMPLEX, PANIPAT (OPTION 2 )

ISSUED FOR FEASIBILITY REPORT OVERALL PROJECT SCHEDULE

(PROPOSED)

DOCUMENT NO.

0 15.02.12 SPS SK TK JGA202‐RP‐2744‐0002‐0

APPV BYREV BYM/s IOCL REV DATE PURPOSE PREP BY

R1

R

R

T

T

T

T

T

MECHANICAL COMPLETION

COMM'G

R

R

R

R

T

R

R

T

R2

R3

R

R



Rev. No. 0

Page 1 of 12




Annexure- II Estimated Project Cost for Check Cases

PROJECT : STYRENE RECOVERY PROJECT, PANIPAT, IOCL

SL. D E S C R I P T I O N ALL COST IN RS. LAKHS JOB NO. A202

NO. Fc Ic TOTAL CLIENT IOCL

LOCATION PANIPAT, HARYANA

1 LAND Excluded

2 SITE DEVELOPMENT 93 93

3 PROCESS KNOWHOW, BASIC ENGG. 24 33 63 24 96 TYPE OF ESTIMATE

START-UP ASSISTANCE & LICENSE FEE

4 DETAIL ENGG., PROCUREMENT, 21 52 21 52

CONST. SUPVN., & PROJ. MGMT. EXECUTION METHODOLOGY

5 PLANT & MACHINERY

5.1 PROCESS UNITS

- STYRENE RECOVERY UNIT 20 KTPA 21 04 92 42 113 47

ESTIMATE VALIDITY

EXCHANGE RATES

1 US $ = ` 55.00

1 Euro = ` 68.00

NOTES

Customs Duty 22.85%

Excise Duty 12.36%

Sales Tax 2.00%

WCT 4.00%

Service Tax on 4.94%

Site Works

Entry Tax NIL

Service Tax 12.36%

Sub-Total (5.1)

(P&M - PROCESS UNITS)21 04 92 42 113 47

5.2 - UTILITY & OFFSITES 11 7 31 7 41

5.3 - CAPTIVE POWER PLANT Not Envisaged

5.4 - PILLING Excluded Ms JAYATI GHOSH

5.5 - CATALYST & CHEMICALS (First Fill) 8 68 2 73 11 42

5.6 - SPM/COT/PIPELINE Not Envisaged

PREPARED BY Manoj / Shiv

Sub-Total (5) - PLANT &

MACHINERY29 84 102 47 132 30

6 ROADS & BUILDINGS 12 12 REVIEWED BY Prachi Gupta

7 WATER SUPPLY & PUBLIC HEALTH Not Envisaged

8 OFFICE EQUIPMENT & FURNITURE Not Envisaged 20 20 APPROVED BY Anil Kumar

9 RAILWAY SIDING Not Envisaged S U M M A R Y

10 CONSTRUCTION SITE REQUIREMENT 1 32 1 32

11 TOWNSHIP 3 90 3 90

12 OWNER'S CONST. PERIOD EXPENSES 53 2 12 2 65

13 START UP & COMMISSIONING EXPENXES 66 66 1 32 DOCUMENT NO. A202-FR-6842-0001

TOTAL ( 1 - 13) 55 36 133 87 189 23 REVISION NO. 1

14 CONTINGENCY @ 5% 5% 2 77 6 69 9 46 DATE : 17/08/2012

TOTAL ( 1 - 14) 58 13 140 56 198 69 PAGE : 1

15 WORKING CAPITAL MARGIN Not required by Owner

TOTAL ( 1 - 15) 58 13 140 56 198 69

16 FINANCING CHARGES 18 48 18 48

TOTAL PROJECT COST … 58 13 159 04 217 17

Format no. 5-6842-1000-F1 Rev.4

PROJECT MANAGER

FILE NAME

D:\Manoj\A202_Styrene

Recovery

Unit_IOCL\Estimate_Rev-

E_Final

Report_R1\[A202_Project

Cost

Summary_Case4.xls]PROJ


PROJECT COST SUMMARY

CAPACITY

Feasibility Report

Conventional

Jun-12

PROJECT : STYRENE RECOVERY PROJECT, PANIPAT, IOCL

SL. D E S C R I P T I O N ALL COST IN RS. LAKHS JOB NO. A202

NO. Fc Ic TOTAL CLIENT IOCL

LOCATION PANIPAT, HARYANA

1 LAND Excluded

2 SITE DEVELOPMENT 4 07 4 07

3 PROCESS KNOWHOW, BASIC ENGG. 36 50 93 37 42 TYPE OF ESTIMATE

START-UP ASSISTANCE & LICENSE FEE

4 DETAIL ENGG., PROCUREMENT, 37 55 37 55

CONST. SUPVN., & PROJ. MGMT. EXECUTION METHODOLOGY

5 PLANT & MACHINERY

5.1 PROCESS UNITS

- STYRENE RECOVERY UNIT 20 KTPA 21 04 92 42 113 47

- TOLUENE / XYLENE EXTRACTION UNIT 220 KTPA 3 86 51 56 55 42 ESTIMATE VALIDITY

EXCHANGE RATES

1 US $ = ` 55.00

1 Euro = ` 68.00

NOTES

Customs Duty 22.85%

Excise Duty 12.36%

Sales Tax 2.00%

WCT 4.00%

Service Tax on 4.94%

Site Works

Entry Tax NIL

Service Tax 12.36%

Sub-Total (5.1)

(P&M - PROCESS UNITS)24 91 143 98 168 89

5.2 - UTILITY & OFFSITES 8 48 33 55 42 03

5.3 - CAPTIVE POWER PLANT Not Envisaged

5.4 - PILLING Excluded Ms JAYATI GHOSH

5.5 - CATALYST & CHEMICALS (First Fill) 18 02 5 61 23 63

5.6 - SPM/COT/PIPELINE Not Envisaged

PREPARED BY Manoj / Shiv

Sub-Total (5) - PLANT &

MACHINERY51 41 183 14 234 55

6 ROADS & BUILDINGS 12 12 REVIEWED BY Prachi Gupta

7 WATER SUPPLY & PUBLIC HEALTH Not Envisaged

8 OFFICE EQUIPMENT & FURNITURE 20 20 APPROVED BY Anil Kumar

9 RAILWAY SIDING Not Envisaged S U M M A R Y

10 CONSTRUCTION SITE REQUIREMENT 2 35 2 35

11 TOWNSHIP 3 90 3 90

12 OWNER'S CONST. PERIOD EXPENSES 94 3 75 4 69

13 START UP & COMMISSIONING EXPENXES 1 17 1 17 2 35 DOCUMENT NO. A202-FR-6842-0001

TOTAL ( 1 - 13) 90 01 237 19 327 20 REVISION NO. 1

14 CONTINGENCY @ 5% 5% 4 50 11 86 16 36 DATE : 17/08/2012

TOTAL ( 1 - 14) 94 51 249 04 343 56 PAGE : 1

15 WORKING CAPITAL MARGIN Not required by Owner

TOTAL ( 1 - 15) 94 51 249 04 343 56

16 FINANCING CHARGES 31 95 31 95

TOTAL PROJECT COST … 94 51 281 00 375 51

Format no. 5-6842-1000-F1 Rev.4

PROJECT MANAGER

FILE NAME

D:\Manoj\A202_Styrene

Recovery

Unit_IOCL\Estimate_Rev-

E_Final

Report_R1\[A202_Project

Cost

Summary_Case4.xls]PROJ


PROJECT COST SUMMARY

CAPACITY

Feasibility Report

Conventional

Jun-12



Rev. No. 0

Page 1 of 7




Annexure- III Equipment List



Rev. No. 0

Page 2 of 7




AIII.0 Equipment List

AIII.I Styrene Recovery Unit.

S.NO. ITEM NO. DESIGNATION MOC

DESIGN PRESSURE

DESIGN TEMPERATURE

kg/cm2g Deg C

VESSELS

1 D-101 DEC7 OH RECEIVER C.S 3.5 & FV 150

2 D-102 DEC8 OH RECEIVER C.S 3.5 & FV 150

3 D-103 FEED SURGE DRUM C.S 3.5 100

4 D-201 HYDRO. PRODUCT SEPARATOR C.S 3.5 100

5 D-202 EDC OH RECEIVER C.S 3.5 & FV 100

6 D-203 SRC OH RECEIVER C.S 3.5 & FV 100

7 D-204 WATER SURGE DRUM C.S 3.5 100

8 D-205 SFC OH RECEIVER C.S 3.5 & FV 150

9 D - 206 EDC FEED DRUM C.S. 3.5 150

10 D -208 1ST STAGE SEPARATOR C.S. 19 150

11 D - 209 2ND STAGE SEPARATOR C.S. 19 150

12 D - 210 LP VENT DRUM C.S. 3.5 & FV 250

13 D - 214 PLANT SOLVENT TANK C.S. 0.02/-0.005 100

14 D - 215 WET SOLVENT TANK C.S. 0.02/-0.005 100

15 D - 216 SOLVENT VENT DRUM C.S. 3.5 & FV 250

16 D - 217 AROMATICS SUMP C.S. 3.5 & FV 250

17 D - 218 SOLVENT SUMP C.S. 3.5 & FV 250

18 D - 219 STIR DRUM 316L SS 3.5 150

19 D - 220 SFC WITHDRAW DRUM C.S. 3.5 & FV 150

REACTORS DESIGN

PRESSURE DESIGN

TEMPERATURE

MOC kg/cm2g Deg C

1 R - 201A/B PA HYDROGENATION REACTOR 1.25Cr-0.5Mo 6.0 & FV 400

COLUMNS DESIGN

PRESSURE DESIGN

TEMPERATURE

SHELL/ TUBES kg/cm2g Deg C

1 C - 101 DEHEPTANIZER COLUMN C.S 3.5 & FV 200

2 C - 102 DEOCTANIZER COLUMN C.S 3.5 & FV 200

3 C - 201 EDC COLUMN C.S 3.5 & FV 200

4 C - 202 SRC COLUMN C.S 3.5 & FV 200

5 C - 203 STYRENE FINISHING COLUMN 316L SS 3.5 & FV 150

6 C - 204 SOLVENT REGENERATOR C.S 3.5 & FV 220

7 C - 205 WATER STRIPPER C.S 3.5 & FV 150

8 C - 206 A/B DRYING COLUMN , C.S 3.5 & FV 150

TANKS kg/cm2g Deg C

1 D - 211 STYRENE PRODUCT DAILY TANK A C.S. 0.02/-0.005 -10 / 65

2 D - 212 STYRENE PRODUCT DAILY TANK B C.S. 0.02/-0.005 -10 / 65



Rev. No. 0

Page 3 of 7





DESIGN PRESSURE

DESIGN TEMPERATURE

EXCHANGERS SHELL SHELL TUBE SHELL TUBE

1 E - 101 DEC7 FEED/DEC8 OVHD HX C.S/ C.S

3.5 & FV 2.5 150 150

2 E - 103 DEC7 REBOILER C.S/ C.S 11 3.5&FV 250 200

3 E - 105 DEC8 REBOILER C.S/ C.S 11 3.5 & FV 250 200

4 E - 106 C7 CUT COOLER C.S/ C.S 7.5 8 100 70

5 E - 108 C9+ CUT COOLER C.S/ C.S 7.5 8 100 70

6 E - 201 HYDRO. PROD. COOLER C.S/ C.S 6.5 8 100 70

7 E - 202 EDC FEED PRE-HEATER C.S/ C.S 11 13 150 150

8 E - 203A EDC CONDENSER C.S/ C.S 3.5 &

FV 8 100 70

9 E - 203B EDC OVHD TRIM CONDENSER (VENT CONDENSER TYPE)

C.S/ C.S 3.5 & FV 8 100 70

10 E - 204A/B EDC REBOILER C.S/

304LSS 7 3.5 & FV 250 200

11 E - 205 SRC CONDENSER C.S/ C.S 3.5 &

FV 8 100 70

12 E - 206 SRC REBOILER C.S/

304LSS 11 3.5 & FV 250 200

13 E - 207 A STEAM GENERATOR A C.S/ C.S 3.5&FV 13 150 200

14 E - 207 B STEAM GENERATOR B C.S/ C.S 3.5&FV 7 150 200

15 E - 208 REACTOR FEED COOLER C.S/ C.S 6.5 11 150 200

16 E - 209 COLOR REMOVER DRUM COOLER C.S/ C.S 5 8 150 70

17 E - 210 LEAN SOLVENT COOLER C.S/ C.S 3.5 &

FV 8 150 70

18 E - 211 SOLVENT REGENERATOR REBOILER C.S/

304LSS 3.5 & FV 11 200 250

19 E - 212 FINISHING CONDENSER C.S/ C.S 3.5 &

FV 8 150 70

20 E - 213 STYRENE PRODUCT CHILLER C.S/ C.S 6 8 70 70

21 E - 214 FINISHING REBOILER C.S/

304LSS 7 3.5&FV 250 150

22 E - 215 FILM EVAPORATOR (VENDOR PACKAGE)

C.S.(Jacket)

316SS(Shell) 7 3.5&FV 150 250

23 E - 216 STYRENE PRODUCT DAILY TANK CYCLE COOLER A

C.S/ C.S 7 8 100 65

24 E - 217 STYRENE PRODUCT DAILY TANK CYCLE COOLER B

C.S/ C.S 7 8 100 65

25 E - 218 STYRENE TANK CYCLE COOLER C.S/ C.S 7 8 70 70

26 E - 219 AROMATIC SUMP COOLER C.S/ C.S 7 8 150 65

27 E - 220 WET SOLVENT COOLER C.S/ C.S 8 8 200 65

28 E - 221 DRYERS REBOILER C.S/ C.S 7 3.5&FV 250 150

29 E - 223 STYRENE PRODUCT COOLER C.S/ C.S 7 8 150 100

DESIGN

PRESSURE DESIGN

TEMPERATURE

AIR COOLERS Fins kg/cm2g Deg C

1 E - 102 DEC7 CONDENSER Al 3.5 & FV 150

2 E - 104 DEC8 CONDENSER Al 3.5 & FV 150

3 E - 107 C9+ CUT COOLER Al 3.5 & FV 150

PUMPS CASING kg/cm2g Deg C

1 P - 101 A/B DEC7 REFLUX PUMP C.S. 7.4 150



Rev. No. 0

Page 4 of 7





DESIGN PRESSURE

DESIGN TEMPERATURE

2 P - 102 A/B DEC7 BTM PUMP C.S. 3.5 200

3 P - 103 A/B DEC8 REFLUX PUMP C.S. 6.5 150

4 P - 104 A/B DEC8 BTM PUMP C.S. 7.5 200

5 P - 105 A/B DEC7 FEED PUMP C.S. 2.1 100

6 P - 201 A/B RECYCLE FEED PUMP C.S. 5.2 100

7 P - 202 A/B EDC REFLUX PUMP C.S. 7.3 150

8 P - 203 A/B EDC WATER PUMP C.S. 3.5 100

9 P - 204 A/B EDC BTM PUMP C.S. 3.7 200

10 P - 205 A/B SRC REFLUX PUMP C.S. 5 150

11 P - 206 A/B SRC WATER PUMP C.S. 3.5 100

12 P - 207 A/B SRC BTM PUMP C.S. 12.7 200

13 P - 208 A/B WATER SURGE PUMP C.S. 4.5 100

14 P - 209 A/B EDC FEED PUMP C.S. 4.4 100

15 P - 210 A/B FINISHING REFLUX PUMP C.S. 4.6 150

16 P - 211 A/B FINISHING COLUMN BOTTOM PUMP C.S. 4.3 150

17 P - 212 A/B FINISHING WATER PUMP C.S. 3.5 150

18 P - 213 A/B FINISHING WITHDRAW PRODUCT PUMP C.S. 5.9 150

19 P - 214 A/B SFC FEED PUMP C.S. 3.6 150

20 P - 215 A/B DRYING COLUMN PUMP C.S. 4.6 150

21 P - 216 A/B HRS RECYCLE PUMP C.S. 2.5 150

22 P - 218 A/B STYRENE DAILY TANK CYCLE PUMP A C.S. 0.8 65

23 P - 219 A/B STYRENE PRODUCT DAILY TANK CYCLE PUMP B C.S. 0.8 65

24 P - 220 STYRENE PRODUCT DAILY TANK PUMP A C.S. 1.9 65

25 P - 221 STYRENE PRODUCT DAILY TANK PUMP B C.S. 1.9 65

26 P - 224 AROMATICS SUMP PUMP (Vertical) C.S. 1.3 250

27 P - 225 PLANT SOLVENT TANK PUMP (Vertical) C.S. 2 100

28 P - 226 WET SOLVENT TANK PUMP (Vertical) C.S. 2 100

29 P - 227 SOLVENT RECOVERY PUMP (Vertical) C.S. 0.9 250

MISCLLENEOUS

1 M-201 WIPED FILM EVAPORATOR PACKAGE With Wiped Film Evaporator(0.01 MW), FLUX OIL SURGE DRUM and PUMPS (2 Nos)

2 M-202 TRUE INHIBITOR INJECTION PACKAGE Drum & Pump CHEMICAL: TRUE INHIBITOR

3 M-203 RETARDER INJECTION PACKAGE Drum & Pump CHEMICAL: MEA

4 M-204 MEA INJECTION PACKAGE Drum & Pump CHEMICAL: MEA

5 M-205 ANTIFOAM INJECTION PACKAGE Drum & Pump CHEMICAL: ANTIFOAM

6 M-206 TBC INJECTION PACKAGE Drum & Pump CHEMICAL: TBC

7 M-207 VACUUM SYSTEM PACKAGE 1 Ejector (or Vacuum Pump) and Auxiliary Equipment




11 M-211 MP STEAM DESUPERHEATER VENDOR PACKAGE



Rev. No. 0

Page 5 of 7




AIII.II Toluene Mixed Xylene Recovery Unit

S.NO. ITEM NO. DESIGNATION MOC DESIGN PRESSURE DESIGN TEMPERATURE

VESSELS kg/cm2g Deg C

1 D-101 *C9+ SPLITTER OVHD RECEIVER C.S 3.5 150

2 D-201 *EDC OVHD RECEIVER C.S 3.5 100

3 D-202 *SRC OH RECEIVER C.S 3.5 & FV 100

4 D-203 *WATER SURGE DRUM C.S 3.5 100

5 D-301 *TOLUENE COLUMN OH RECEIVER C.S 3.5 150

6 D-302 *# COLUMN OH RECEIVER C.S 3.5 200

7 D-204 *SOLVENT VENT DRUM C.S 3.5 250

8 D-205 *SOLVENT SUMP C.S. 3.5 250

COLUMNS DESIGN PRESSURE DESIGN TEMPERATURE

SHELL kg/cm2g Deg C

1 C - 101 *C9+ SPLITTER C.S 3.5 250

2 C - 201 *EDC C.S 3.5 250

3 C - 202 *SRC C.S 3.5 & FV 250

4 C - 203 *SOLVENT REGENERATOR C.S 3.5 & FV 250

5 C-301 *TOLUENE COLUMN C.S 3.5 250

6 C-302 *#XYLENE COLUMN C.S 3.5 250

TANKS DESIGN PRESSURE DESIGN TEMPERATURE

SHELL kg/cm2g Deg C

1 TK-201 *PLANT SOLVENT TANK C.S 0.1 100

2 TK-202 *WET SOLVENT TANK C.S 0.1 100

EXCHANGERS

SHELL/ TUBES

SHELL TUBE SHELL TUBE

1 E-101A/B

*C9+ SPLITTER FEED PREHEATER

C.S/C.S 3.5 150 150

2 E-103 *C9+ SPLITTER REBOILER C.S/C.S 20.4 3.5 350 200

3 E-104A/B *TX CUT COOLER C.S/C.S 8 10 100 65

4 E-106 *C9+ HEAVIES TRIM COOLER C.S/C.S 8 10 100 65

5 E-203 *EDC REBOILER C.S/C.S 20.4 3.5 350 250

6 E-205 *SRC OVHD TRIM COOLER

C.S/C.S 8.0/ FV 10 100 65

7 E-206 *SRC REBOILER C.S/C.S 20.4 3.5/ FV 350 250

8 E-207 *STEAM GENERATOR C.S/C.S 15 19 150 200

9 E-208 *SOLVENT REGENERATOR HEATER

C.S/C.S 20.4 3.5/ FV 350 250

10 E-209 *EDC FEED PREHEATER C.S/C.S 15 19 150 150

11 E-210 *WATER PREHEATER C.S/C.S 15 19 150 150

12 E-211 *RAFFINATE COOLER C.S/C.S 8 10 100 65

13 E-212 *EDC SIDE REBOILER C.S/C.S 15 19 250 250

14 E-301 *EXTRACT PREHEATER 1 C.S/C.S 9 7 100 150

15 E-302 *EXTRACT PREHEATER 2 C.S/C.S 10 13 150 200



Rev. No. 0

Page 6 of 7




16 E-304 *TOLUENE COLUMN REBOILER C.S/C.S 20.4 3.5 350 200

17 E-305A/B *TOLUENE PRODUCT TRIM COOLER C.S/C.S 11 10 100 65

18 E-308 *XYLENE PRODUCT TRIM COOLER C.S/C.S 12 10 100 65

19 E-309 *#XYLENE COLUMN REBOILER C.S/C.S 50 3.5 427 250

DESIGN PRESSURE

DESIGN TEMPERATURE

AIR COOLERS Fins kg/cm2g Deg C

1 E-102 *C9+ SPLITTER OVHD CONDENSER Al 3.5 150

2 E-105 *C9+ HEAVIES COOLER Al 3.5 250

3 E-201 *LEAN SOLVENT AFTER COOLER Al 17 150

4 E-202 *EDC CONDENSER Al 3.5 150

5 E-204 *SRC OVHD CONDENSER Al 3.5/ FV 150

6 E-303

*TOLUENE COLUMN OVHD CONDENSER

Al 3.5 150

7 E-306

*#XYLENE COLUMN OVHD CONDENSER

Al 3.5 200

8 E-307 *XYLENE PRODUCT COOLER Al 3.5 150

9 E-213 *WET SOLVENT COOLER Al 3.5 250

PUMPS CASING kg/cm2g Deg C

1 P-101A/B *C9+ SPLITTER REFLUX PUMP C.S.

150

2 P-102A/B *C9+ SPLITTER BOTTOMS PUMP C.S.

200

3 P-201A/B *EDC REFLUX PUMP C.S.

100

4 P-202A/B *EDC WATER PUMP C.S.

100

5 P-203A/B *EDC BOTTOMS PUMP C.S.

250

6 P-204A/B *SRC REFLUX PUMP C.S.

100

7 P-205A/B *SRC WATER PUMP C.S.

100

8 P-206A/B *SRC BOTTOMS PUMP C.S.

250

9 P-207A/B *DECANT WATER PUMP C.S.

100

10 P-301A/B *TOLUENE COLUMN REFLUX PUMP C.S.

150

11 P-302A/B *TOLUENE PRODUCT PUMP C.S.

100

12 P-303A/B

*TOLUENE COLUMN BOTTOMS PUMP

C.S.

200

13 P-304A/B *#XYLENE COLUMN REFLUX PUMP C.S.

200

14 P-305A/B

*#XYLENE COLUMN BOTTOMS PUMP

C.S.

250

15 P-208 *PLANT SOLVENT TANK PUMP C.S.

250

16 P-209 *WET SOLVENT TANK PUMP C.S.

250

17 P-210 *SOLVENT SUMP PUMP (Vertical) C.S.

250

AIII.III Offsite Area

TANKS DESIGN PRESSURE DESIGN TEMPERATURE

SHELL kg/cm2g Deg C

1 TK-301 STYRENE STORAGE TANK CS

Positive : Full of liquid + 200 MMWC, Vacuum : 50 mm WC -10/ 65

2 TK-302 A/B *TOLUENE STORAGE TANK CS

Positive : Full of liquid + 150 MMWC, Vacuum : 50 mm WC 65

3 TK-303 A/B *#MIXED XYLENES STORAGE TANK CS

Positive : Full of liquid + 150 MMWC, Vacuum : 50 mm WC 65



Rev. No. 0

Page 7 of 7




1 P - 222 A/B STYRENE TANK CYCLE PUMP C.S.

65

2 P - 223 A/B STYRENE PUMP C.S.

65

3 P - 401 A/B *TOLUENE PUMP C.S.

65

4 P - 402 A/B *#XYLENE PUMP C.S.

65

MISCELLANEIOUS

1 CH-301 CHILLER SYSTEM

2 VP-301 *VAPOUR RECOVERY SYSTEM FOR TOLUENE LOADING

*Applicable for option -2 only # Not to be consider for the case ‘without xylene column (splitter)



Rev. No. 0

Page 1 of 4




Annexure- IV Hook ups



Rev. No. 0

Page 2 of 4




AIV.0 Hook-Up Points

AIV.I Preliminary Process Hook-up Points

* Flare load to be obtained from Licensor, presently under hold.

Notes-

1. Preliminary hook-up location, to be confirmed after detailed study based on Licensor input, final P&ID and engineering study during DFR/execution stage.

HPG

To SRU Raffinate

From SRU

TP

To 11-E-5003 Gasoline

Product Cooler 4”-P-120-1310-B1DG-P

4” 4”

To 13-EA-5702/13-E-5704 Dehexanizer Condenser / C7+

Product Cooler

6”-P-357-1304-A1D-P

6”

6”

20”-P-68-2401-A1A

60”-WF-180-1102-A1K-N

Wet Flare

From SRU/T/X Unit

Hold*

TP TP TP

TP

TP

C7+

To T/X Unit

Raffinate

From T/X Unit

TP

NCU Off-Sites



Rev. No. 0

Page 3 of 4




2.The other products i.e. Styrene, Toluene and mixed-Xylenes will be routed to storage through new lines.

AIV.II Preliminary Utilities Hook-up Points

CW

Supply CW

Return

TP

Note-3

30” MH

20”

TP

OSBL NCU

108”-WCS-70-1291-A91A B

20”

OSBL NCU

B 108”-WCR-70-1291-A91A

6”-HS-173-1701-D1AX-H

4”

TP

HP

Steam

TP

MP

Steam LP

Steam

TP

24”-MS-173-1706-B1AX-H

14” 10”

24”-LSS-173-1703-A1AX-H

Condensate

TP

20”-LC-173-1101-A2A-P

8”

Note-3

30” MH



Rev. No. 0

Page 4 of 4




Notes-

1. All the hook-up points are preliminary. To be decided based on final Licensor input/P&ID and hook-up study by engineering at the time of DFR/execution. 2.Overall plant existing line adequacy check to be ensured during final hook-up identification. 3.Feasibility of suggested hook-up needs to be checked during execution




A202-RP-0241-0001

Rev. No. 0

Page 1 of 7

Format No. EIL 1641-1924 Rev. 1 Copyright EIL – All rights reserved

Appendix V Overall Block Flow Diagram




A202-RP-0241-0001

Rev. No. 0

Page 2 of 7


AV.0 Overall Block Flow Diagram

Overall Block flow diagrams (for both the cases i.e. standalone Styrene recovery unit

or Styrene recovery with Mixed Xylene/Toluene extraction unit ) is as under :

AV.I Standalone Styrene Recovery Unit

Styrene recovery unit is consisting of Feed Preparation section and Styrene

Extraction section.

AV.I.I Pre-fractionation Section

The Pre-fractionation section is consist of Deheptanizer and Deoctanizer Colums

along with its associated facilities. It separate from HeavyPygas into C7- cut , C9+ cut

and C8 styrene concentrate . C8 styrene concentrate further sent to Styrene

extraction section and C7- cut , C9+ cut sent to B/L .

AV.I.II Styrene Extraction Sections

Styrene Extraction Sections separates styrene from C8 styrene concentrate. Rest of

C8 raffinate sent to B/L and Styrene will go through further processing (drying and

purification).

AV.II Styrene Recovery Unit With Mixed Xylene/Toluene Extraction Unit

Apart from above unit Mixed Xylene/Toluene Extraction Unit will recover Mixed

Xylene and Toluene from BzEU raffinate by extractive distillation method.

FEASIBILITY REPORT FOR RECOVERY OF

STYRENE, TOLUENE / MIXED XYLENES

A202-RP-0241-0001

Rev. No. 0

Page 3 of 7


CASE-I : STANDALONE STYRENE RECOVERY UNIT



A202-RP-0241-0001

Rev. No. 0

Page 4 of 7


CASE-II : STYRENE RECOVERY UNIT WITH MIXED XYLENE/TOLUENE EXTRACTION UNIT




A202-RP-0241-0001

Rev. No. 0

Page 5 of 7


AV.III OFFSITE STORAGE FACILITIES

Schematic process flow diagrams (for both the cases of options are as given below :

Case 1 : PFD for Offsite Facility with standalone Styrene recovery unit

Case II : PFD for offsite facility with integrated Styrene recovery with Mixed

Xylene/Toluene extraction unit.



A202-RP-0241-0001

Rev. No. 0

Page 6 of 7


CASE 1 : As Built Storage Facilities + New Facilities



A202-RP-0241-0001

Rev. No. 0

Page 7 of 7


Case II : As Built Storage Facilities + New Facilities


STYRENE, TOLUENE / MIXED XYLENES ,

IOCL, PNCP, PANIPAT

A202-RP-0241-0001

Rev. No. 0

Page 1 of 14


Appendix VI Schematic Process Flow Diagrams



IOCL, PNCP, PANIPAT

A202-RP-0241-0001

Rev. No. 0

Page 2 of 14


AVI.0 Schematic Process Flow Diagrams

Schematic process flow diagrams (for both the cases i.e. standalone Styrene

recovery unit or Styrene recovery with Mixed Xylene/Toluene extraction unit ) is as

under :

AVI.I Styrene Recovery Unit

Main Sections of the Styrene Recovery units are as follows:

Prefractionation Section

Refer IOCL –PFD-001,

PA Selective Hydrogenation Section & Extractive Distillation Section

Refer IOCL –PFD-002

Solvent Regeneration and Steam Generation Section


Dryers and Color Treatment Section & Styrene Finish Column Section


Polymer Removal System Section


Styrene and Solvent Storage Section

This section is mainly used for styrene day tanks products, fresh solvent make-up

and wet solvent storage. Refer IOCL –PFD-005

The Styrene storage tanks are to be located in the Offsite Area. For PFD Refer

IOCL –PFD-005

FEASIBILITY REPORT FOR RECOVERY OF STYRENE,

TOLUENE / MIXED XYLENES , IOCL, PNCP, PANIPAT

A202-RP-0241-0001

Rev. No. 0

Page 3 of 14




A202-RP-0241-0001

Rev. No. 0

Page 4 of 14




A202-RP-0241-0001

Rev. No. 0

Page 5 of 14




A202-RP-0241-0001

Rev. No. 0

Page 6 of 14




A202-RP-0241-0001

Rev. No. 0

Page 7 of 14




A202-RP-0241-0001

Rev. No. 0

Page 8 of 14




IOCL, PNCP, PANIPAT

A202-RP-0241-0001

Rev. No. 0

Page 9 of 14


AVI.II Toluene/ Xylene Recovery Unit

Schematic process flow diagrams for the cases of integrated Styrene recovery with

Mixed Xylene/Toluene extraction unit is as under :

Main Sections of the Styrene Recovery units are as follows:

Prefractionation Section

Refer IOCL –PFD--001,

Extractive Distillation Section


Solvent Regeneration and Steam Generation Section


Post Fraction Toluene Recovery Section

Refer IOCL –PFD-003B

Post Fraction Xylene Recovery Section

Refer IOCL –PFD-004B

Toluene / Xylene Solvent Storage Section

This section is mainly used for day tanks, fresh solvent make-up and wet solvent

storage. Refer IOCL –PFD-005

The Toluene & Mixed Xylene Styrene storage tanks are to be located in the Offsite

Area.

FEASIBILITY REPORT FOR RECOVERY OF STYRENE, TOLUENE /

MIXED XYLENES , IOCL, PNCP, PANIPAT

A202-RP-0241-0001

Rev. No. 0

Page 10 of 14




A202-RP-0241-0001

Rev. No. 0

Page 11 of 14




A202-RP-0241-0001

Rev. No. 0

Page 12 of 14




A202-RP-0241-0001

Rev. No. 0

Page 13 of 14




A202-RP-0241-0001

Rev. No. 0

Page 14 of 14



Document No.A202-RP-0241-0001-AVII

Rev. No. 0 Page 1 of 4



Annexure- VII Unit Layout

800,000 TPA ETHYLENE PLANT PANIPAT, INDIAPANIPAT NAPHTHA CRACKER PROJECT

INDIAN OIL CORPORATION LIMITED

A ISSUED FOR COMMENTS

A726

Rectangle


Document No. A202-RP-0241-0001-AVIII

Rev. No. 0

Page 1 of 2




Annexure- VIII Overall Plot Plan

iathd`r dk;kZy; % bathfu;lZ bafM;k Hkou] 1] Hkhdk,th dkek Iysl] ubZ fnYyh&110066

Regd. Office : Engineers India Bhawan, 1, Bhikaiji Cama Place , New Delhi – 110066

Date post:	10-Jul-2018
Category:	Documents
Upload:	phamkhanh
View:	224 times
Download:	1 times

FEASIBILITY REPORT FOR RECOVERY OF STYRENE,...

Documents