IPCL NAGOTHANE

8/11/2019 IPCL NAGOTHANE

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IPCL NAGOTHANE

Presented By

Saurabh Thakur and Monish Sutradhar



INTRODUCTION

• Nagothane Manufacturing Division is located

near Raigad, Maharashtra.

• It comprises of an ethane and propane gas

cracker and five downstream plants for themanufacture of polymers, fibre intermediates

and chemicals.



Plants at IPCL Nagothane

Name of Plant Commissioned Year

Gas Cracker 1992

LDPE Plant 1992

Butene-1 Plant 1992

LLDPE / HDPE

Plant

1993

Polypropylene Plant 1990

MEG/Ethylene Oxide Plant 1992



Products and Brands

• Company has expanded rapidly and integratedbackwards into other industry sectors, mostnotably the production of petrochemicals and the

refining of crude oil.• Operations that span from the exploration and

production of oil and gas to the manufacture ofpetroleum products, polyester products,

polyester intermediates, plastics, polymerintermediates, chemicals and synthetic textilesand fabrics.



Products and Brands

• The Company's operations can be classified

into four segments namely:

• Petroleum Refining and Marketing business

• Petrochemicals business

• Oil and Gas Exploration & Production business

•Others

• The Company has the largest refining capacity

at any single location.



Products and Brands

The Company is:

• Largest producer of Polyester Fibre and Yarn

•

5th largest producer of Paraxylene (PX)• 5th largest producer of Polypropylene (PP)

• 8th largest producer of Purified Terephthalic

Acid (PTA) and Mono Ethylene Glycol (MEG)



Process Description

Crude Oil Refining



What is Crude Oil

• Crude oil, also known as black gold, is a thick, darkbrown or greenish flammable liquid, which is found inthe upper strata of some regions of the Earth's crust

• It is a complex mixture of various hydrocarbons,

(mainly, alkanes), along with trances of otherchemicals and compounds (e.g. Sulphur)

• When extracted from underground, it ranges in densityfrom very light to very heavy and in color, from yellowto black

• Crude oil can be categorized as either "sweet crude"(where the sulphur content less than 0.5%) or "sourcrude," (where the sulphur content is at least 2.5%)



What is Crude Oil

Crude oil must undergo severalseparation processes so that itscomponents can be obtained

and used as fuels or convertedto more valuable products

The process of transformingcrude oil into finished

petroleum products (that themarket demands) is calledcrude oil refining



Distillation of Crude Oil

• We can separate the components of crude oilby taking advantage of the differences in theirboiling points. This is done by simply heating

up crude oil, allowing it to vaporize, and thenletting the vapor to condense at differentlevels of the distillation tower (depending ontheir boiling points). This process is called

fractional distillation and the products of thefractional distillation of crude oil is calledfractions



Distillation of Crude Oil

• A fraction from crude oil can be categorizedinto two categories:

– Refined Product: A crude oil fraction which

contains a lot of individual hydrocarbons(e.g. gasoline, asphalt, waxes, andlubricants)

– Petrochemical Product: A crude oil fractionwhich contain one or two specifichydrocarbons of high purity (e.g. benzene,toluene, and ethylene).



AT THE TOP OF

THE

DISTILLATION

COLUMN

AT THE BOTTOM

OF THE

DISTILLATION

COLUMN

Short carbon

chains

Long carbon

chains

Light molecules Heavy molecules

Low boiling

points

High boiling points

Gases & very

runny liquids

Thick, viscous

liquids

Very volatile Low volatility

Light colour Dark colour

Highly flammable Not very

flammable

Crude Oil Refining



Fractions of Crude Oil & Their Properties

NameNumber of

Carbon Atoms

Boiling Point

(°C)Uses

Refinery Gas 3 or 4 below 30 Bottled Gas

(propane or butane).

Gasoline 7 to 9 100 to 150 Fuel for car

engines.

Naphtha 6 to 11 70 to 200 Solvents

and used in gasoline.

Kerosene (paraffin) 11 to 18 200 to 300 Fuel for aircraft

and stoves.

Diesel Oil 11 to 18 200 to 300 Fuel for road vehicles

and trains.

Lubricating Oil 18 to 25 300 to 400 Lubricant for engines and machines.

Fuel Oil 20 to 27 350 to 450 Fuel for ships

and heating.

Greases and Wax 25 to 30 400 to 500 Lubricants

and candles.

Bitumen above 35 above 500 Road surface and roofing.



Chemical Processing

• The fractions from crude oil are liable to undergo chemical processing to alter itsstructure and thus its properties

• The sort of chemical processing employed depends largely on the market demand

• Examples of chemical processes are as the following:

• Cracking: the process obtaining relatively simple and small hydrocarbon

molecules from the breaking down of large, heavier and more complexhydrocarbon molecules.

• Coking: the process of breaking down bitumen into its fractions (done bya Coker)

• Alkylation: A process where the structure of a hydrocarbon molecule inone fraction is altered to produce another hydrocarbon molecule withanother structure. In alkylation, compounds with a low molecular weight,

such as propylene and butylene, are mixed in the presence of a catalystsuch as hydrofluoric acid or sulfuric acid

• Unification: a process where two or more hydrocarbons are combined toproduce a larger one. The major unification process is called catalyticreforming and occurs in the presence of a catalyst (platinum, platinum-rhenium mix) to combine low weight naphtha into aromatics



Treatment Processes

• Chemical sweetening, acid treating, clay contacting, caustic washing,hydro treating, drying, solvent extraction, and solvent dewaxing.Sweetening compounds and acids desulphurize crude oil beforeprocessing and treat products during and after processing.

• Clay Treating

– Use clay to soak up and remove unwanted components in petroleum

• Dilute the oil with solvent and freeze the oil

– During the freezing process, wax will be solidify leaving only the pure oil inliquid phase

• Acid treating – Using concentrated sulphuric acid to convert sludge from the oil

– Expensive

• SO2 Treating

– Using a very toxic recyclable solvent to remove the worst components in oil



Treatment: The Finishing Touch

• Impurities such as organic compounds containing sulphur, nitrogen, oxygen, water,dissolved metals and inorganic salts must be removed from the distillated andchemically processed fractions

• Treating is typically done by passing the fractions through the following:

• a column of sulphuric acid - removes unsaturated hydrocarbons(hydrocarbons with carbon-carbon double-bonds), nitrogen compounds,oxygen compounds and residual solids (tars, asphalt)

• an absorption column filled with drying agents to dehydrate the fraction

• sulphur treatment and hydrogen-sulphide scrubbers to remove sulphurand sulphur compounds

• Today, a major portion of refining involves blending, purifying, fine-tuning and

improving products to meet specific requirements• Example: Refinery workers carefully blend together a variety of hydrocarbons to

make petrol. Moreover to distinguish the various grades of fuel, technicians addperformance additives and dyes. At the end of the production of petrol, the petrolcontains more than 200 hydrocarbons and additives

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