LuPech Project, LAB Revamp & N-Butanol PRE...

PRE-FEASIBILITY REPORT

LuPech Project, LAB Revamp & N-Butanol


Project No Unit Document Serial No Rev Page

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TABLE OF CONTENTS

A – LuPech Project Details

1. Project Objective .............................................................................................................. 3

2. Project name and Location ............................................................................................. 3

3. Plant Design Capacity ..................................................................................................... 4

4. Raw Material Quality ........................................................................................................ 4

5. Product Quality ................................................................................................................ 4

6. Catalysts and Chemicals ................................................................................................. 4

7. Utilities and Offsites ........................................................................................................ 5

8. Product Evacuation ......................................................................................................... 9

9. Plant and Non-Plant building .......................................................................................... 9

10. Project Execution Philosophy ....................................................................................... 12

11. Project Implementation Plan ......................................................................................... 12

B – LAB Revamp & N-Butanol Project Details

LAB Revamp & N-Butanol Project description ........................................................................... 25

C – Conclusion .............................................................................................................................. 33

Attachments – LuPech Project

I. Overall Block Flow Diagram

II. Process Description

III. Raw Materials and Products

IV. Catalyst and Chemicals

V. Project Schedule


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1. Project Objective

Indian Oil Corporation (IOC) is raising the capacity of its Gujarat refinery as well as setting up a petrochemical plant at the unit as part of plans for upscaling petchem business to protect margins. This project is referred to as “LuPech Project”.

The project envisages raising the capacity of the Vadodara refinery in Gujarat from 13.7 million tonnes per annum to 18 million tonnes and building a 0.5 million tonnes a year polypropylene (PP) plant and a 2,70,000 tonne a year Lube Oil Base Stock (LOBS) unit. "The project would be a building block for the production of niche chemicals in future with a potential to increase petrochemical and specialty products integration index on incremental crude oil throughput which would enhance the corporate margins of IOC. The Gujarat refinery project is part of IOC's plans to boost petrochemical capacity by more than 70 per cent over the next decade, from 3.2 million tonnes a year currently.

The Units that are newly installed under the LuPech Project are listed below.

o Vacuum Distillation Unit o SR LPG Treater Unit o INDMAX FCCU including CR LPG Treater Unit o Propylene Recovery Unit o Polypropylene Unit o OCTAMAX Unit o Naphtha Splitter Unit o Naphtha Hydro Treater Unit o Isomerisation Unit o Sulphur Recovery Unit o Amine Regeneration Unit o Sour Water Stripper Unit o LOBS (CDW / HDF) Unit o Associated Offsites and Utilities

The units that are undergoing revamp under the LuPech Project are listed below.

o Atmospheric Unit - 5 o Hydrocracker Unit o FCC BS-VI GDS Unit

2. Project name and Location

The location details of Gujarat Refinery are listed below.

State / Country : GUJARAT / INDIA Nearest Railway Station : VADODARA Nearest Town / City : VADODARA


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Nearest Airport : VADODARA Nearest National Highway : NH-8 Nearest Port : DAHEJ

3. Plant Design Capacity

The design capacities of different units of LuPech project are as indicated in the below table,

Unit Unit No. Capacity

SR LPGTU 1802 65 TMTPA

Indmax FCC including CR LPG Treater unit 1803 2700 TMTPA

NSU 1805 800 TMTPA

Propylene Recovery Unit 1806 580 TMTPA

Polypropylene Unit (PP) 1807 500 TMTPA

NHT 1808 360 TMTPA

ISOM 1810 360 TMTPA

Sulphur Recovery Unit (SRU) 1812 400 MTPD

Sour Water Stripper (SWS) 1813 330 TPH

Amine Regeneration Unit(ARU) 1814 350 TPH

New VDU 1831 2500 TMTPA

OCTAMAX 1832 110 TMTPA

LOBS (CDW/HDF) 1833 277 TMTPA

AU-V Revamp 05 7.3 MMTPA

HCU Revamp 06 1550 TMTPA

FCC BS-VI GDS Revamp 603 700 TMTPA

Offsites & Utilities - As Required

4. Raw Material Quality

Refer Attachment- 3 that summarizes the Raw material specifications for each process unit that forms part of LuPech.

5. Product Quality

Refer Attachment- 3 that summarizes the Product specifications for each process unit that forms part of LuPech.

6. Catalysts and Chemicals


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Refer Attachment- 4 that summarizes the catalysts, and chemicals for each process unit that forms part of LuPech.

7. Utilities and Offsites

7.1 Utilities

The table below summarizes the total requirement, capacity and source of all new utilities required for LuPech project.

Utility System

UOM LuPech Total

Design Requirement

Source

Cooling water

m3/hr

48,000

Supplied from CT-1 of 16,000 m3/hr + CT-2 of 32,000 m3/hr capacity.

Instrument Air Nm3/hr 16,400

Catered from New Compressed Air system – 3 x 8200 (2W+1S) Plant Air Nm3/hr

Gaseous N2 Nm3/hr 5000 Catered from New Nitrogen Generation Plant Liquid N2 Storage m3 500

HP Steam TPH 450 3 x 150 TPH Utility Package Boiler

DM Water m3/hr 500 3 (2W+1S) New DM Trains of 250 m3/hr each; Condensate Polishing Unit

m3/hr 250 2 trains of CPU (1W + 1S)

Raw water MGD (UK) 10 New Radial wells at banks of Mahi river. Effluent Treatment Facility m3/hr 385 New ETP for LuPech.

7.2 Offsites

Raw material

Existing crude storage facilities will be used for crude storage and no new facilities are envisaged.

Intermediates & Products

In line with scope of LuPech project, the following storage facilities are envisaged at Offsite facilities.

a) NHT Feed Storage Tank


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New NHT feed storage tanks will receive cold Naphtha produced from AU-V Revamp unit and existing secondary processing unit. The stored Naphtha will be pumped to New Naphtha Splitter Unit that forms part of LuPech MS Block for further processing.

Two new NHT feed storage tanks each of 12000 KL capacity will be installed along with transfer pumps of 300 m3/h capacity each (2W+1S).

b) MTO Storage Tank

MTO is a new product envisaged in post LuPech scenario. A new MTO Storage tank of 5000 KL capacity will be installed along with 350 m3/h capacity transfer pumps (1W+1S) to cater to the storage requirement of this new product.

c) Propylene Bullet

Four new Propylene bullets each of 3500 KL capacity to be installed along with transfer pumps of 72 m3/h capacity (2W+1S).

These propylene bullets act as intermediate storage for High Purity Propylene produced from PRU and provides feed holdup for downstream Polypropylene unit.

d) LPG Bullets

Four new LPG bullets each of 3000 KL capacity to be installed along with transfer pumps of 300 m3/h capacity (1W+1S) to handle the incremental LPG produced as part of LuPech. LPG from Refinery shall be transferred to DUMAD area through the existing pipeline. No new pipeline is envisaged.

LPG Intermediate transfer pumps requirement to be confirmed based on final location of LPG bullets.

e) Waxy 70N/150N LOBS Feed Tank

Two new Waxy 70N/150N LOBS Feed Tank each of 2000 KL capacity to be installed along with transfer pumps of 17.4 m3/h capacity (1W+1S).

These LOBS feed tanks act as intermediate storage for Waxy 70N/150N produced from HCU Revamp and provides feed holdup for downstream LOBS unit.

f) Waxy 500N LOBS Feed Tank

Two new Waxy 500N LOBS Feed Tank each of 4000 KL capacity to be installed along with transfer pumps of 23.5 m3/h capacity (1W+1S).

These LOBS feed tanks act as intermediate storage for Waxy 500N produced from HCU Revamp and provides feed holdup for downstream LOBS unit.

g) 70N Lube oil Tank

Existing 70N Lube oil Tank (3000 KL x 2) and (1000 KL x 2) tanks are used for storage.


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h) 150N Lube oil Tank

Three new 150N Lube oil Tank each of 3000 KL capacity to be installed to cater to the storage requirement of this new product.

i) 500N Lube oil Tank

Four new 500N Lube oil Tank with capacity 6500 KL x 3, 3000 KL x 1 to be installed to cater to the storage requirement of this new product.

j) Lubes Slop tank

A new lubes slop tank with 40 KL capacity to be installed along with transfer pumps of 50 m3/h capacity (1W+1S).

All other intermediates and products that are in LuPech scope will be utilizing existing storage facilities available in Gujarat Refinery.

7.3 Electric Power

Source of Power Grid / Existing substations Volts at Design Stage Refer below for individual substation Frequency at Design Stage

50Hz

Rate Rs./kWH To be provided by IOCL Distance in km from the power supply Available point to unit

Substation for FCC/CR LPG + New VDU+SR LPG & AU-V Revamp units (ESS-044)

1250 m (Approx.) (From 33kV GIS for BS-VI Project at Existing CGP-1 SS)

Substation for PRU/OCTAMAX & Cooling Water Package (ESS-042)

PRU & Octamax Units:- 1500 m (Approx.) (From 33kV GIS for J18 Project at Grid power import SS) CT Package: - 1800 m (Approx.) (From Existing SS (CGP-2) at 33kV level) (See Note-1)

Switch room for Compressed Air Package / Lube oil tanks / Propylene & LPG Bullets (ESS-043)

1000 m (Approx.) (From Utility Electrical System at MS Block SS (ESS-045) at 6.6kV level (See Note-1)

Substation for MS Block & Utility Units (ESS-045)

(See Note-2)

3000 m (Approx.) (From 33kV GIS for J18 Project at Grid power import SS) (See Note-1)


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Substation for PPU unit. (ESS-

046)

1100 m (Approx.) (From 33kV GIS for J18 Project at Grid power import SS)

Substation for ETP Package. (ESS-047)

1100 m (Approx.) (From 33kV GIS at Existing Substation (ESS-038))

Substation for Sulphur Block (SRU/SWS/ARU) unit (ESS-048)

1100 m (Approx.) (From 33kV GIS at Existing Substation (ESS-038))

Substation for LOBS unit. (ESS-049)

500 m (Approx.) (From 11kV Switchboard at Existing Substation (ESS-026))

NHT & MTO Tanks / Raw Water System /

To be fed from nearby existing substations at 6.6kV & 0.415kV levels, which need to be identified.

Emergency Power for Process & Utility Units

From Existing Substation (CGP-1) at 11Kv level for FCCU, New AVU, SR LPG & AU-V Revamp Units. (1250 m (Approx.) – For ESS 044.

630 kVA DG Set at 0.415kV level for PRU, Octomax & Cooling Tower Package (CT-1 & CT-2). (Near ESS-042)

2000 kVA DG Set at 0.415kV level for MS Block Units. (Near ESS- 045)

2 x 2750 kVA DG Set at 6.6kV level for Utility Block Units. (Near ESS- 045) – See Note -2

2000 kVA DG Set at 0.415kV level for PPU unit. (Near ESS-046)

2000 kVA DG Set at 0.415kV level for Sulphur Block & ETP Package. (Near ESS-047)

315 kVA DG Set at 0.415kV level for LOBS unit. (Near ESS-049)

Note 1: The Cooling Water Circulation pumps are fed from ESS-042 (Captive Power Source)

& ESS-046 (Grid Power Source) The Compressor Air system motors are fed from Existing SS, ESS-033 (Captive

Power Source) & MS/Utility Block substation, ESS-045 (Grid Power Source) The N2 Compressor motors are fed from Existing SS, ESS-033 (Captive Power

Source) & MS/Utility Block Unit Substation, ESS-045 (Grid Power Source)

Note 2: The Utility Block Unit includes DM Plant+ZLD+CPU, Boilers-1, 2 & 3, N2 Package & Propylene Bullets

Note 3: Refer Attachment 4.3 – Electrical Power Distribution Philosophy for LuPech Project


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8. Product Evacuation

The dispatch modes of various products that are impacted by LuPech project are summarized in the table below.

S No

Product

Post LuPech Requirement,

TMTPA

Pipeline

Road

Rail

1 MTO 120 0 100% 0

2 ATF 650 100% 0 0

3 MS 4727 100% 0 0

4 HSD 8012 100% 0 0

5 Sulfur 200 0 100% 0

6 Fuel Oil 250 0 0 100%

7 PP 500 0 100% 0

8 LPG 1045 100% 0 0

9 70N 50 30% 70%

10 150N 50 30% 70%

11 500N 135 30% 70%

For all the distillates, existing dispatch facilities will be utilized. For Lube products, new truck loading system (3 bays) and dedicated loading system (100 loading arms) in existing wagon loading facility are provided as part of Lupech project. For PP new truck loading facilities are provided.

9. Plant and Non-Plant building

9.1 Construction Site Facilities and Fabrication Yard

Zone Units Area Available in SQ.M

KOYALI FCCU, IGHDS (Incl. CR & SS) 1,25,000

CALICO MS Block, Propylene Bullets & Utilities (Incl. CR & SS)

1,75,000

BAJWA PPU, PPU Warehouse & IETP, PRU and CT2 (Incl CR & SS)

2,35,000

9.2 Buildings

Administrative Building Not envisaged

Warehouse (Chemical, Spares, Product, Cement)

1. Chemical ware house and Peroxide storage in PPU

2. Chemical store room in CT-1


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3. Chemical store room in CT-2

4. Room for Peroxide Feed (Part of the extruder building)

5. Room for Vacuum degassing (Part of the extruder building)

Workshop Not envisaged Canteen Not considered Central Laboratory Not envisaged Control rooms for Plant Operation

Refer Attachment-4.4

There are 4 new control rooms, 2 Local control rooms and 2 Satellite Rack Rooms (SRR):

1. Control Room for FCC+CR LPG 2. Control Room for MS Block 3. Control Room for PPU+ PRU +CT 1 & 2 +

Octomax 4. Control Room for Utilities 5. Extension of existing control room for AVU 5

revamp, New VDU and SR-LPG 6. Local Control Room for N2 generation and

storage 7. Local Control Room for ETP. 8. Local control room for Instrument Air and Plant

Air compressor. 9. Local control room for truck loading. 10. Local control room for Extruder including room

for VFD panel room 11. Local control room for Bagging plant. (Inside the

warehouse) There are 4 existing control rooms as follows:

1. GR-1 (AU-V) Control Room:

a. Remote DCS, ESD, FDS I/O cabinets required for interfacing signals associated to Amine & sour water storage tanks shall be installed in this existing control room, which shall be controlled and monitored from the control room for Indmax FCC (control room number 2, above).

b. For AU-V revamp, existing spares of existing control & safety system in this control room shall be used for interfacing signals associated to AU-V Revamp and controlled and monitored from the existing GR-1 (AU-V) control room.

2. North Block Control Room:

a. Existing spares of existing control & safety system


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in this control room shall be used for interfacing

signals associated to new NHT storage tanks and control & monitoring from this existing North Block control room.

b. Remote DCS, ESD, FDS I/O cabinets required for interfacing signals associated to new MTO storage tanks shall be installed in this existing North Block control room, which shall be controlled and monitored from the existing OM&S Control room.

3. OM&S Control Room:

Existing spares of existing control, safety system & Tank Farm Management System (TFMS) in this existing control room shall be used for interfacing signals associated to new MTO storage Tanks and Propylene mounded bullets including tank gauging instruments. Control and monitoring of these tanks shall be from this existing OM&S Control room.

4. Existing Control Room at Dumad Existing spare of existing control & safety system in this control room shall be used for interfacing signals associated to new LPG bullets.

Satellite Rack room (SRR) One SRR for SRU+SWS+ARU and another SRR for ZLD

conference rooms Considered within control room building

Training Center Not Required

Substations Refer Attachment-4.3

There are 7 new substations & 1 Switch Room to feed J18 Project units:

1. SS for PRU, Octomax & Cooling Tower Package (ESS-042)

2. Switch Room for Compressed Air Package, Lube oil tanks/Propylene & LPG Bullets (ESS- 043)

3. SS for FCC/CR LPG+VDU+SR LPG+AU-V Revamp units (ESS-044)

4. SS for MS Block+ Utility Units (ESS-045) 5. SS for PPU Unit (ESS-046) 6. SS for ETP Package (ESS-047) 7. SS for Sulphur Block Unit (ESS-048) 8. SS for LOBS Unit (ESS-049)

Electrical system for Raw Water package, and NHT & MTO Tank area are to be fed from nearby existing substations, which need to be identified.


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Fire Station Not considered PP Ware House Considered for 17 days of Inventory Lab Lab in PPU

10. Project Execution Philosophy

This project execution is considered in two parts.

PMC-1: Design phase (BDEP/ FEED preparation, +10% cost estimate, DFR, Tendering, Evaluation and recommendation for Tendering activities

PMC-2: Execution phase (Detailed engineering, Procurement, Construction, Commissioning)

11. Project Implementation Plan

The Capacity expansion plan has undergone changes with IOCL’s focus being shifted

towards Petrochemical and Lube Integration in the Gujarat Refinery through process reconfiguration. Accordingly following major changes have been made as part of process reconfiguration

New AVU is cancelled and replaced with revamping of the existing AU-5 capacity

from 3 MMTPA to 7.3 MMTPA along with addition of new VDU of 2.5 MMTPA SR LPG Capacity changed from 200 KTPA to 65 KTPA Polypropylene Unit Capacity Revised from 420 KTPA to 500 KTPA New LOBS unit with 235 KTPA (with associated feed &product tanks and Product

handling system) is added with feed from existing HCU. Revamp of existing HCU New OCTAMAX Unit of 110kTPA is added IGHDS and KGHDS Units are deleted CCRU in MS Block is deleted and NHT (2400KTPA) and ISOM(925 KTPA)

capacities reduced to 360 KTPA (for both) and new NSU of 800KTPA added PRU : no change Capacity, but Heat Pump Compressor driver has been changed

from Steam turbine to Electric Motor Indmax FCCU: No Capacity change, but GDS unit shifted to BS-VI BS-VI GDS Quality Revamp No capacity changes in,CRLPG, SRU, ARU,SWS

PMC had completed FEED for all units as per Original expansion plan and for the revised and finalized process configuration, the project execution will be as follows:

For units with no change in capacities, there will be minor updates in FEED by PMC . For (i) the new units, (ii) the units with revised capacities and (iii) Revamp of existing Units, Basic Design Engineering Package will be done by Licensor (except for open art process unit VDU by PMC ) followed by Front End Engineering Design performed by PMC. Associated updates of O&U design will also be performed by


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PMC.

Subsequently the project will be executed in three modes as described in 19.1.2

For units under LSTK mode of execution (refer 19.1.2.1) PMC scope also includes development of tender documents up to Techno-Commercial Recommendation to Client.

11.1 OVERALL PROJECT EXECUTION

Lupech project with revised process configuration shall be executed in three modes of project execution:

11.1.1 LSTK MODE

Some of the process units shall be executed through LSTK Mode of project execution with TPIL as the PMC. The details are as under:

S.No UNIT DESCRIPTION FACILITY MODE OF EXECUTION

TPIL ROLE

1 INDMAX FCC / CRLPG PROCESS LSTK-2 PMC

2 Polypropylene Unit PROCESS LSTK-3 PMC

3 New VDU & SR LPG PROCESS LSTK-4 PMC

4 MS Block – NSU / NHT / ISOM PROCESS LSTK-5 PMC

5 Propylene Recovery Unit PROCESS LSTK-6 PMC

6 LOBS Unit PROCESS LSTK-8 PMC

7 OCTAMAX PROCESS LSTK-9 PMC

11.1.2 LEPC MODE

The following process units shall be executed through LEPC Mode of project execution with TPIL as the PMC. The details are as under:

S.No UNIT DESCRIPTION FACILITY MODE OF EXECUTION

TPIL ROLE

1 CR LPG TU * PROCESS LEPC PMC

2 Sulphur Recovery Unit PROCESS LEPC (LSTK-7) PMC

* - CR LPG treater unit will be in LEPC mode and executed by Indmax FCCU LSTK contractor (LSTK-2-2)


11.1.3 CONVENTIONAL (EPCM) MODE

The balance process units and Utilities & offsite including interconnection with the existing refinery complex shall be executed under EPCM mode of execution. The details of execution shall be as under:

S.No.: UNIT DESCRIPTION MODE OF

EXECUTION TPIL

ROLE

1 AU-V Revamp (Capacity expansion from 3MMMTPA to 7.3 MMTPA)

EPCM EPCM

2 Sour Water System EPCM EPCM 3 Amine Regeneration Unit EPCM EPCM

4 BS-VI GDS Quality Revamp EPCM EPCM

5 HCU Revamp EPCM EPCM

6 Offsites & Utilities EPCM EPCM 7 Interconnection with Existing Refinery EPCM EPCM

O & U packages are issued as LSTK to the suppliers including all design, engineering, procurement, inspection ,testing, packing, transportation, supply and erection, mechanical compketion including Precommissioning upto commissioning and handover of the entire package item.

11.2 Project Organization

The following organizations shall operate effectively and cooperate with each other to make this project success:

IOCL Management Organization (Owner) TPIL (PMC) LSTK Contractors Vendors, manufacturers, Suppliers and contractors

11.2.1 IOCL (Owner)

IOCL as owner has awarded the projection execution to TPIL as per the modes of execution defined above. IOCL role shall include monitoring of PMC works and deliverables, coordination with different stake holders of the project, management of all financing matters, maintaining community relations and to obtain all statutory approvals/permits required for project execution. A Project Manager along with his multi-discipline team shall be vested with suitable powers, responsibility and accountability by IOCL Management to monitor the project execution. Project Manager from IOCL shall lead the Project team from IOCL side.

11.2.2 TPIL (PMC)


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This project shall be executed by Chennai office of TPIL with certain support from Noida office of TPIL. The organization of PMC will be headed by a dynamic Project Director and supported with Project Deputy director. Project team at Chennai shall be the single point responsible for carrying out the project, assuming the overall responsibility for the execution of the project as per the agreed schedule and the agreed implementation strategy.

The complete project team shall be responsible for planning, monitoring, coordination, supervision and control of the entire project. The project team shall be supported by a dedicated group of various engineering, process, purchase, inspection and construction personnel. Project director and Project Deputy Director shall be responsible to strategies, guide, direct, monitor and control the project.

PMC will act as an extended arm of owner i.e. IOCL and shall always keep in view IOCL’s interest and advising/guiding Owner on all important matters, to ensure that the project is completed with the best possible cost, time and quality.

11.2.3 LSTK Contractors

LSTK contractor shall be selected through competitive bidding process in a transparent and competitive tendering process. Based on the techno-commercial recommendations provided by PMC, IOCL shall appoint competent LSTK contractors for execution of EPC/ LSTK portion. LSTK contractor shall be responsible to execute the complete projects as per the requirements and standards indicated in the contract following best engineering practices in a transparent and ethical manner. LSTK contractor shall appoint a Project Manager for the project.

The LSTK Contractor shall provide efficient and motivated Project Management team with adequate number of members from start of WORKS till completion of all facilities covering all phases of the Project execution. The Contractor shall ensure compliance to OISD, PESO, IBR etc guidelines and all other statutory regulations.

LSTK Contractor shall fully co-operate with IOCL and PMC project management team to make the execution of the project a success. During the execution of the project, EPC contractor shall interact and cooperate with other contractors and third parties representatives duly authorized by IOCL/PMC.

LSTK contractor shall employ a dedicated team of well qualified and experienced specialists and experts from various discipline on various aspects of Project execution but not limited to namely:

Project Management Project Scheduling & Control Process Design Engineering QA/QC Management Inspection & expediting


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Procurement, Materials Management & Logistics Construction Pre-commissioning / Commissioning HSE management at site HR and administration Finance and accounts

11.3 PMC’S SCOPE OF WORK AND EXECUTION METHODOLOGY:

The PMC’s scope of work for the revised process configuration shall include the following as a minimum:

Upto award of contracts Preparation of BDEP for New VDU, PRU, ARU, SWS, Offsite & Utilities

FEED Dossier for New VDU, SRLPG, FCC, , MSBLOCK (NSU/NHT/ISOM), PRU, PPU, New VDU,LOBS Unit, OCTAMAX Unit, AU-5 Revamp ,HCU- Revamp, BS-VI GDS Quality Revamp ARU, SWS, Offsite & Utilities

Preparation of ±10% Cost Estimation HAZOP Study (For newly added sections) Preparation of Procedures and Master Schedule Finalization of project plot plan Prequalification of Bidders, Bid-preparation and Tendering of LSTK/ Packages

Contracts After award of contractsOverall Project Management Approval of Designs/ Drawings of LSTK Contractors/ Vendors Supervision of LSTK contractors Detailed Engineering of EPCM scope Procurement and expediting services of EPCM scope Mechanical Completion of EPCM scope Construction Management including supervision, Assistance in Start-up,

Commissioning & Performance Test Runs of EPCM scope

11.3.1 ACTIVITIES TO BE PERFORMED BY PMC

PMC shall perform following activities: Develop project scope and procedures for the entire project. Prepare Master Network for the entire project and update the same at regular

intervals. Identify the critical activities and monitor closely to ensure adherence to the overall

project schedule. Prepare major milestones for the entire project including that of LSTK works and

closely monitor them. Develop an appropriate MIS reporting covering project status, controlling and

feedback information for mid-term corrections, Organize and participate in regular project review meetings, monthly at

Headquarter level and daily/weekly at site or as required Submit fortnightly / monthly/ flash reports on HO & Site Services.


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11.4 Project Scope of work and Execution Methodology of EPCC/LSTK/ contractor

The brief scope of work and activities required to be performed by the LSTK/EPCC/LEPC contractors include but not limited to the following:

Project Management Validation of FEED given by PMC Residual Process Design Detailed Engineering (including HAZOP/SIL study) Procurement Quality Assurance/ Quality control Inspection & Expediting Procurement of LLI and critical items and Co-ordination with vendors Supply of all non-LLI equipment / materials Insurance Transportation of all equipment / materials to work site Handling & Storage of all Equipment, Materials at site Fabrication Construction Installation Testing, Pre-commissioning & Commissioning Performance Guarantee Test Run (PGTR) Handing over of all the facilities to IOCL including supply of mandatory spares,

commissioning spares, O & M spares during defect liability period and Supply of Chemicals & lube oils for pre-commissioning, commissioning & PGTR and Catalysts as per the bidding document along with Final and “As Built”

documentation to the OWNER/CONSULTANT, on single point responsibility basis.

11.4.1 Engineering

The LSTK Contractor will carry out all engineering work in house. The LSTK Contractor shall provide all engineering specifications, drawings and documents necessary to construct the complete facilities. The engineering design shall be performed in accordance with all requirements stipulated in the ITB document.

In case the Contractor does not have in house resources for any specialized activity, the same may be carried out through third party agency if already declared in bidding and accepted by PMC/IOCL. Contractor shall ensure that the agency is reputed and has adequate relevant experience. Contractor shall take full responsibility for the work carried out by the agency.

PMC shall review all important design documents and drawings highlighted in Tender provided by LSTK contractor/PACKAGE VENDOR to ensure consistency and adherence to contractual engineering specifications and adherence to QA/QC plans.


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During the LSTK Contractor’s engineering and design activities, PMC will monitor the

progress and ensure adherence to the Contract and Project schedule. PMC may schedule visits by its lead engineers, on need basis, to the Contractor’s Office in home country or in India, to review specific engineering and design deliverable, to provide clarifications and to help in removing bottlenecks, if any. Regular reports of such visits and of supervision undertaken by PMC at Contractor’s office will be furnished to Owner for information/recommended action, as necessary.

11.4.2 Procurement

The LSTK Contractor shall perform all necessary pre-order and post order procurement work for all the LLI/critical/ /non-LLI items and materials in accordance with requirements in the ITB.

The Contractor shall co-ordinate with the vendors for obtaining necessary inputs for engineering and perform procurement services. The Contractor shall also be responsible for transportation of materials to site, equipment handling, storage, erection, pre-commissioning and commissioning.

PMC will perform close supervision of Procurement activities of contractors to ensure timely delivery of materials to adhere to the schedule.

11.4.3 Construction

The Contractor shall be responsible for the construction of the facilities on schedule, according to the approved codes and standards, contract specifications and drawings, and responsible for the workmanship of high quality and use of the equipment and materials in accordance with good construction practice. The Contractor shall provide all labor, construction equipment, tools and tackles, materials, consumables, temporary facilities, construction utilities and so on, and support services for the construction work.

The Contractor is deemed to have full knowledge of applicable codes and standards, laws and regulations, conditions of labor, local conditions and environmental aspects and shall comply with the requirements thereof. IOCL shall be kept indemnified by the Contractor for any violation.

11.4.4 Temporary Facilities

The Contractor shall design, supply, construct and maintain the temporary facilities such as Site office, fabrication yard, storage, ware house, utilities required for site job, etc. as per the project requirements.


077154C 000 RT 0008 005 0 18 of 24


077154C 000 RT 0008 005 0 19 of 24


For manufacturing of ODC items such as columns, site fabrication space will be provided within the refinery.

For all other items, LSTK contractor shall make necessary arrangements outside the refinery and bring materials ready to be erected due to space constraints. Contractor shall plan erection activities accordingly.

In addition to the Construction power provided by IOCL (if available) on payable basis, the Contractor shall make his own arrangements for the supply and maintenance of construction power until Mechanical Completion.

The Contractor shall make his own arrangements for the supply of construction and potable water through bore hole or other means as specified in tender.

The Contractor shall dismantle, remove and relocate the temporary facilities after completion of the project at his own cost

11.4.5 Pre-commissioning & Commissioning

The Contractor shall perform the pre-commissioning and commissioning work for the Process units/facilities under EPC contract in accordance with requirements of the project. PMC shall ensure that all the pre-commissioning/commissioning activities of the Project are carried out by LSTK contractor/other agencies in accordance with established procedure, schedules and program.

11.4.6 Quality Assurance

a) Vendor Shop Inspection The Contractor shall be responsible for providing an inspection and quality management program, which shall ensure that IOCL is provided with equipment and materials that meet the requirements of the Project.

PMC shall prepare the inputs for completing Inspection and Quality Assurance Program of the contractors, which will provide IOCL with acceptable and quality products. The Contractor shall perform the procurement inspection through approved third party inspection agencies in accordance with the requirements of the Project and agreed inspection & test plans (ITPs).

b) Construction Quality

The Contractor shall apply the required field inspections and tests as required by the Contractor’s quality management program and agreed ITPs. This program shall additionally

ensure that all inspection and test required by Government regulatory bodies are completed. The Contractor shall have in effect an inspection control program which shall be approved


077154C 000 RT 0008 005 0 20 of 24


by IOCL/PMC prior to start of work in order that construction activities are performed in accordance with approved drawings and specifications, applicable codes and standards and contractual requirements.

PMC shall carry out a Construction Quality Audit of the project facility every three months during construction phase of the project by an independent group of PMCs personnel not reporting to the site in-charge. PMC shall carry out a Risk Analysis on the Construction activities regularly and publish a monthly report on the Risk Analysis perceived and the Mitigation plans. Monthly update on the Analysis also given for corrective actions.

c) Pre-commissioning Inspection

The Contractor shall ensure that erected facilities conform to flow diagrams, construction drawings, suppliers’ documents, and specifications as per the requirements of the Project. PMC/Owner shall deploy personnel to review the reports of inspection of the contractor.

11.4.7 Planning, Scheduling & Costing

The Contractor shall plan and schedule all activities and report to IOCL/ PMC in accordance with the requirements of the Project.

The Contractor shall provide a computer interface to OWNER/ PMC, which shall be linked to the Contractor's Planning and Scheduling System. The Contractor shall submit the total estimated Bill of quantities for all materials of piping, fitting, electrical, instrument and civil at the start of facilities and update this as the detail engineering and material take off is finalized.

11.5 Project Scope of work and Execution Methodology of LEPC contractor

The responsibilities of LEPC contractor includes all the responsibilities defined for EPCC/LSTK contraction, in the above section. In addition to the above, the licensor selection, basic engineering and FEED are included in LEPC contractor scope of work.

11.6 Project Scope of work and Execution Methodology of EPCM contractor

PMC shall be the Single point responsibility for execution of units in Conventional mode and offsite and utilities.

PMC shall have the responsibility of managing, coordinating and executing the work assigned by IOCL. A full-time Project Manager will be assigned to liaison with the Vendors/ contractors and will be responsible for all aspects of job execution including safety. He will ensure all necessary co-ordination, flow of information and timely issue of design documents and drawings. Regular Progress Reports will be issued to IOCL highlighting progress achieved, major milestones, areas of concern and actions required.


077154C 000 RT 0008


005 0 21 of 24

11.6.1 Engineering

All design and engineering works will be carried out from the offices of the consultant. A review Board consisting of Senior Management personnel from the PMC will be formed to ensure that proper quality, safety and progress of work for the assigned job is maintained.

PMC shall provide all engineering specifications, drawings and documents necessary to construct the complete facilities. The engineering design shall be performed in accordance with all requirements stipulated in the ITB document.

11.6.2 Procurement Services

PMC shall perform the pre-order and post order procurement services for all indigenous & imported equipment and materials except for constructions materials like:

Civil items like sand, cement, reinforcement bars, steel structure, fire proofing

material, aggregates, bricks, timber etc Electrical items like light fitting, junction box and cable boxes etc, Instrument items like SS tubes and tube fitting, valves and manifold, junction box and

cables gland. and any other material, fitting, fixtures which would be supplied by construction contractors concerned.

The above is only an indicative list of items, however scope of procurement shall include all equipment and items as necessary to make the systems complete.

11.6.3 QA/QC services

PMC’s services during the detailed engineering phase will include identification of the

requirement of contractor’s field engineering cell, development review, and monitoring of QA and QC Plans and to review and recommend changes in the scope of work by Contractors and other contractors and associated extra claims if any.

11.6.4 Expediting & Inspection Services

PMC shall perform the Expediting services of the indigenous equipment and materials. For imported materials, expediting shall be carried out by the IOCL. Inspection of materials/ equipment procured by IOCL/ Contractor shall be carried out by Third party. Inspection of materials at site, inspection of Construction Work shall be carried out by PMC.

11.6.5 Construction Management

PMC’s staff shall supervise construction works for this project to be carried out by works

contractors (EPCM) as per standard test plans. PMC shall position competent person at site office for facilitating smooth correction of drawings as well as for co-ordination of jobs. During the progress of all work to be done at site, PMC shall keep a competent Engineer-in-Charge


at site fully authorized to give and receive such orders as may be necessary for the proper performance of works.

11.6.6 Pre-commissioning, Assistance in Start-up & Commissioning

PMC shall assist IOCL in pre-commissioning, start-up, Commissioning and Performance Test Run including all check lists, flushing schemes etc. The on the ground manpower required for the Process units (EPC part of execution) plant operators, maintenance staff and other associated manpower shall be provided by the EPC contractor.

11.7 Route survey for ODC Movement

Provision has been made to fabricate all the major ODC equipment at site like reactor, regenerator, columns, silos, hoppers and large drums. The space provision and the transportation of the same has been studied and identified in the constructability report.

For the equipment other than above, the following may be noted:

a) Equipment transportation up to Refinery Gate

All the major ODC equipment as indicated above are being fabricated within the refinery complex, therefore need was not felt to carry out the route survey outside the refinery for transportation of such equipment. However, for the purpose of route references, the route survey report which is recently been carried out by IOCL for BS VI project by ACCI has been used.

b) Equipment transportation within the Refinery Complex

The route for transporting the equipment from the refinery gate to the unit plot has been identified in the overall plot plan and the same has been described in the constructability report.

11.8 Soil Investigation

The soil investigation report issued by Unique Engineering Services (Job N0-180122-98), as provided by IOCL has been utilized. No separate Soil investigation has been carried out as part of DFR. LSTK contractor shall perform additional soil investigation for design of structures / foundations when required during execution phase.

11.9 Barricading and Labour Movement

Since some of the units are being constructed within the Running Refinery, proper care has to be taken to ensure minimal disturbance to the refinery during construction stage. Therefore, following points have been considered as part of the safety:


077154C 000 RT 0008 005 0 22 of 24


a) In order to provide safe working environment for carrying out Hot Work during construction, barricading of the construction area unit at appropriate location has been considered. Water curtain with Hydrocarbon gas detectors shall be considered.

b) Isolated areas where hot work is required to be done for shorter and predefined period, work permit from the refinery shall be obtained before starting Hot Work. No barricading is considered for such areas like offsite piping, pipe rack extensions, pipe sleepers, cable pulling and pipe/cable supports as necessary.

c) Separate Labour entry and approach have been identified and shall be used with proper barricading to provide stray movement of Labour force in the refinery during construction. For LSTK Contracts, Contractor shall perform above.

11.10 Constructability Study

A complete constructability study has been carried out as part of DFR to ensure the smooth and timely construction of the units. Constraints if any have been identified and mitigated as part of this report. Following parameters have been considered:

a) IOCL shall provide all plots where facilities are being installed Free of Incumbrancers

before the mobilization of the respective area contractor’s mobilization. b) Strengthening of areas and additions of roads wherever necessary within the refinery

have been considered. c) ODC equipments shall be fabricated near the unit area while other installations shall be

installed after the movement of the ODC equipments from the TCF area.

Refer CHAPTER-12 for complete constructability Study

12. Project Schedule

Refer Attachment- 5 that summarizes the entire LuPech project schedule.

12.1 Important Project Milestones

PMC shall prepare a detailed Planning schedule for the execution of the project in line with the broad schedule specified by the contract. The definition of some of the project Milestones as defined in the contract document shall be as under:

a) Zero date: Effective date of contract, which shall be the date of Fax of Acceptance

issued by owner, accepting CONTRACTOR’s bid.

b) Mechanical Completion: Completion of plant and make it ready for start-up as defined in the contract.

c) Plant commissioning: Pressing into service the units, equipments, vessels,

pipelines, machinery and systems & subsystems comprised with in the plant in accordance with procedures as approved in plant specific operating manual and as


077154C 000 RT 0008 005 0 23 of 24


per the requirement of process licensor / open art units which is the subject matter of the contract after successful testing and trial run of the plant.

d) Plant Guarantee Run: The test runs as per standard test methods, carried out to

demonstrate the ability of the units to meet the values of capacity, product specification, stability of the unit and other performance criteria, as defined for the guaranteed performance level for each unit.


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LAB REVAMP & N-BUTANOL PROJECT DESCRIPTION

Introduction

Linear Alkyl Benzene Unit (LAB) was commissioned in Aug 2004 with an production capacity of 1,20, 000 MTPA of LAB. The LAB Complex includes Kerosene Prefractionation Unit, the Distillate Unionfining Unit, the Molex Process Unit (comprising the “Front End Units”), the Pacol Process Unit, the PEP Process Unit, the Detal Process Unit (comprising the “Back End Units”), and the Hot Oil System. In the Front End section n- paraffin is made from Kerosene and this n-paraffin is fed to PACOL unit in Back End Section. Linear Alkyl Benzene(LAB) is produced in Back End Section by reacting treated Pacolate (from PEP) and Benzene using heterogeneous non-corrosive catalyst to form LAB Objective: Increasing the capacity of LAB complex to 135% of the original design capacity or 162,000 MTA of LAB product Basis This study identifies which major pieces of equipment will require modification or replacement to achieve the target capacity The basis of the study was a single feed case with a Low molecular weight (“LMW”) LAB product (having a molecular weight in the range of 235-239) and a high molecular weight (“HMW”) LAB product (having a molecular weight in the range of 239-243). As per the feasibility study Front End section of LAB Complex can be revamped for 35% capacity increase over the name plate capacity, while in the BE section of the LAB plant, the capacity increase can be by 40% over the name plate capacity. Hence, LAB production can be increased to 162 KTA with 135 % revamp Kerosene Prefractionation unit The primary purpose of the Kerosene Prefractionation Unit is to prepare a kerosene heart cut (nominally C10-C13 range) that contains the n-paraffins that, after hydro processing and selective recovery, will meet the desired molecular weight and light/heavy tail requirements for the LAB product. All equipment was evaluated for both the HMW Case and the LMW Case with a normal paraffin product capacity 130 KMTA. Preliminary evaluation indicates that the HMW Case will govern most of existing equipment sizing. The LMW Case operation will govern the Feed Surge Drum, Feed-Rerun Bottoms Exchanger, Rerun Column Net Bottoms Cooler, Feed Pumps and Rerun Column Bottoms Pumps. The Stripper Column and Rerun Column trays appear to be adequate. However the trays require a more detailed evaluation in the next phase. Rerun Column packing needs to be replaced with higher capacity packing. The Feed-Rerun Pump around Exchanger requires a identical shell in parallel for revamp requirement. The Stripper Column Condenser requires additional rows or bays to meet the revamp requirement. For the Feed–Rerun Bottoms Exchanger, the existing exchanger and one shell of the identical exchanger installed already to meet the revamp requirement. All other equipment appear to be adequate.

D istillate Unionfining Unit The Distillate Unionfining Process Unit hydro treats a kerosene range material to meet the Molex Process Unit feed specifications. The flow scheme is typical of a hydro-processing unit and consists of a reactor section, makeup gas section and a stripping section. The feed to the unit is a kerosene “heart cut” (C10-C13 range) from the Rerun Column in the Kerosene Prefractionation Unit.There is nitrogen in the feed at about the 8 wt. ppm level. Also there is

chlorides of up to 3 wt. ppm in the feed. This unit was not designed for any chlorides in the feed. Chlorides can lead to stress corrosion cracking of the valve trims in the Separator and Stripper overhead. It is recommended to upgrade air cooler tubes and header to Alloy 625. In addition the piping from the air cooler to the Separator will be upgraded to Alloy 625 replacing the 300 series stainless steel valve trims for these services with Monel trims. To achieve the revamp capacity, the Reactor internals need major modifications or replacement. An additional shell of exchange be added in series to the Combined Feed Exchanger in order to retain the existing Product Condenser. The operating pressures of the 3rdand the 4th stages of the Makeup Gas Compressor needs to be raised in order to reduce the volumetric flow of the inlet gas. For the Stripper Overhead Trim Condenser, replace the existing exchanger to increase the operational flexibility of the Stripper. Molex Process Unit The Molex Process is a adsorptive separation method that utilizes molecular sieves for the separation of n-paraffins from branched and cyclic hydrocarbons. The separation occurs in the liquid phase under isothermal conditions. Hydotreated kerosene from Unionfining is feed to the Molex Unit All equipment was evaluated for both the High Molecular Weight case (HMW) and the Low Molecular Weight (LMW) case. The majority of the equipment was governed by the HMW case. The feed rate for both cases was set at rates to produce 130 KMTA n-paraffins.New Raffinate Bottoms Trim Cooler is required. The extract Column bottoms trim cooler can be replaced with Raffinate Bottoms Trim Cooler. The existing trays in Raffinate Column and Extract Column need to be replaced with new UOP Simul Flow Trays and PFMD High Capacity trays, respectively. The Desorbent Stripper needs to be replaced with a new column or the existing shell be retained, the trays replaced with high-capacity ECMD trays and relaxing the desorbent specifications.The existing tube bundles need to be replaced with High Flux tube bundles within the Raffinate Column Reboiler, Desorbent Stripper Reboiler and Extract Column Reboiler. An additional shell in series is required for the Raffinate Column Bottoms-Desorbent Exchanger. Replacement impellers are required for the Chamber Circulation, Raffinate Column Overhead, Raffinate Column Bottoms, Raffinate Column Side cut, Desorbent Stripper Bottoms, Extract Column Bottoms, Extract Column Side cut and Desorbent Pumps. The Charge Pumps need to be operated in parallel. All other equipment appears to be adequate.

P acol with DeFine Process Unit

The Pacol Process is a fixed bed catalytic process to selectively dehydrogenate a high purity, normal paraffin feed to the corresponding mono-olefin product. A DeFine reactor downstream reduces the di- olefins in the Pacol product. A stripping column is provided to remove light ends from the product before it is sent to the PEP unit.

P EP Process Unit

The Pacol Enhancement Process (PEP) unit is a fixed bed adsorption unit for the selective removal of aromatic components from the Pacol product stream. Existing adsorbers will be adequate for the revamp conditions. However, once the unit is in operation, an adjustment in cycle time may be required. It is expected that the desorbent and purge rates are to maintain the same as originally designed. Hence, all the equipment downstream of the adsorbers will be suitable for the revamp conditions. Due to changes in the Detal Unit, the temperature of the desorbent entering the PEP Unit has increased. As a result, two new coolers are required to replace the existing Desorbent-Pacolate Exchanger which will be deleted for the revamp. The design of the coolers will be such that the purge exchangers

(Pacolate-Purge Exchanger and Purge Heater) will be adequate. Detal Process Unit The Detal Process is a catalytic process to alkylate benzene with linear olefins to prepare linear alkylbenzene (LAB).All equipment was evaluated for both the High Molecular Weight (estimated LAB MW = 240.8) and the Low Molecular Weight (estimated LAB MW = 237.2) feed cases.For the revamp study, 20% increase in Detal catalyst volume based on 12% paraffin to olefin conversion in the Pacol Unit. Also, the Benzene to Olefins ratio remain unchanged at 30:1, reduced splits in the Recycle Paraffin Stripper, and the proposed re-use of the Detal’s regenerant benzene effluent as desorbent to the PEP unit (for assessing the Benzene Column). It requires modifications to Detal Reactor that include either increasing the effective tangent length or replacing existing reactors with two new reactors.Implementing new benzene flow scheme utilizing spent regenerant benzene as desorbent in the PEP unit to reduce the benzene circulation load.Retaining all of the columns in the Detal Unit as-is, with the exceptions of the Benzene Column trays and the contact condensing packing of the Recycle Paraffin Stripper and Paraffin Column.In order to supply the additional cooling duty required for revamp operation, the addition of three new water trim coolers is required. These services are the Paraffin Column, LAB Column, and Finishing Column overheads.All the exchangers appear to be adequate for the Detal Process Unit with the exceptions of the Reactor Charge Heater, Benzene Column Reboiler, Paraffin Column Reboiler, LAB Clay Treater Effluent Exchanger, Finishing Column Reboiler, Finish Column Preheater, Net LAB Trim Cooler, Benzene Column Condenser, Paraffin Column Overhead Cooler, and Finishing Column Overhead Cooler, which may require replacement or modification.Most of the pumps appear to require either replacement or modification for the Detal Process Unit with the exception of the Desorbent Pumps, Benzene Column Bottoms Pumps, Recycle Paraffin Stripper Bottoms Pumps, Paraffin Column Bottoms Pumps, LAB Column Bottoms Pumps, and Off-Spec Pump which appear to be adequate for the revamp operation.

H ot Oil Unit

The Hot Oil System is a heat source for a number of exchangers within the LAB Complex. The transfer of heat is accomplished by pumping hot oil (Therminol 66) through a recirculation network between the various complex units. After the exchange of heat, the cooled oil is returned to the Hot Oil Surge Drum. The accumulative heat loss from the hot oil users is replenished with a fired heater that increases the hot oil temperature back up to the original supply temperature.No apparent revisions are required to the hot oil system. UTILITY SUMMARY: AS-BUILT

Sr. No.

Utility Unit Prefract- ionation

Unionfin- ing

Molex Pacol PEP Detal Hot Oil

Common

Total

1 HPS tph 0.0 0.0 0.0 0.0 0.0 0.0 -25.6 0.0 -25.6

2 MPS tph 0.0 0.0 0.0 -1.5 0.0 0.0 -4.0 0.0 -5.5

3 LPS tph 0.0 0.0 0.0 1.5 0.0 0.0 25.6 3.3 30.4

4 BFW tph 0.0 0.0 0.0 0.0 0.0 0.0 0.0 -3.3 -3.3

5 Cold Cond.

tph -1.5 0.0 0.0 0.0 0.0 0.0 0.0 0.0 -1.5

6 Loss tph 1.5 0.0 0.0 0.0 0.0 0.0 4.0 0.0 5.5

7 CW m3/hr -98.8 -148.8 -82.0 -56.3 -62.8 -259.2 -51.9 0.0 -759.7

8 Service Water

m3/hr

-10.0 -10.0

9 Drinking Water

m3/hr

-15.0 -15.0

10 Instrument Air

Nm3/hr

-320.0 -320.0

11 Plant. Air Nm3/hr

-20.0 -20.0

12 Nitrogen Nm3/hr -57.8 -8.7 0.0 -17.3 0.0 -1136.0

-12.0 0.0 -1231.8

13 Fuel Gas (Note 1)

kg/hr 0.0 -171.0 0.0 -1010.0

0.0 0.0 -7484.0 -363.0 -9028.0

14 Fuel Oil (Note 2)

kg/hr 0.0 0.0 0.0 0.0 0.0 0.0 -8455.0 0.0 -8455.0

15 Power (Absorbed)

kW -370.8 -1624.3

-658.1 -3363.3

-220.6 -1245.7

-805.7 0.0 -8288.5

Notes

1. Flow rate is based on Fuel Gas only. 2. Flow rate is based on Fuel Oil only.

UTILITY SUMMARY: POST REVAMP

The estimated utility requirements after revamp are tabulated below:

Sr. No.

Utility Unit Prefract- ionation Unionfin-

ing Molex Pacol PEP Detal Hot Oil Common Total

1 HPS tph

-26.4

-26.4

2 MPS tph

-1.5

-2.2

-3.7

3 LPS tph

1.5

26.4 3.3 31.2

4 BFW tph

-3.3 -3.3

5 Cold Cond.

tph -1.5

-1.5

6 Loss tph 1.5

2.2

3.7

7 CW m3/hr -188.7 -131.6 -143.6 -281.1 -54.8 -383.5 -9.7

-1192.8

8 Service Water

m3/hr

-10.0 -10.0

9 Drinking Water

m3/hr

-15.0 -15.0

10 Instrument Air

Nm3/hr

-320.0 -320.0

11 Plant. Air

Nm3/hr

-20.0 -20.0

12 Nitrogen

Nm3/hr -59.8 -8.7

-17.3

-1136 -12.0

-1233.8

13 Fuel Gas (Note 1)

kg/hr

-143

-2125

-10832 -363 -13463

14 Fuel Oil (Note 2)

kg/hr

-12780

-12780

15 Power (Absorbed)

kW -450.1 -1843.3 -1064.0 -3933.8 -235.8 -1398.5

-804.7 0.0

-9730

Notes

1: Flow rate is based on Fuel Gas

only. 2: Flow rate is based on Fuel

Oil only.

The incremental annual utility consumption post revamp will be.

• Power = 1441.5 KW

• Cooling water = 433.1 m3/hr =3464800 m3/year

• Fuel = 4.4 tph =35200 MT/year • DM water = 1 m3/hr = 8000 MT/year

Prefractionation Adequate (Yes/No) Comments Stripper Column Yes Vessel adequate. Trays marginally

adequate. More detailed evaluation of trays in next phase.

Rerun Column Yes Vessel adequate. Trays marginally adequate. Contact condenser packing should be replaced. More detailed evaluation of trays in next phase. Replace contact condenser packing.

Unionfining Adequate (Yes/No) Comments Charge Heater Yes No change foreseen. Reactor Yes Vessel adequate, but new Internals

required. Stripper Yes Shell and trays are adequate. Review

bottom trays with vendor in next phase

Combined Feed Exchanger

No Add another shell in series

Recycle Gas Compressor Yes Add pilot operated pressure relief valve because of lower pressure margin.

Make-up Gas Compressor No Maximize first two stages, then make up with PSA H2.Increase operating pressure of 3rd and 4th stages.Modification to control scheme recommended. Add pilot operated relief valves because of lower margin

Molex Adequate (Yes/No) Comments Adsorbent Chambers Yes Adequate. Adsorbent Chamber Control System

No change

Rotary Valve Yes Adequate. Raffinate Column Yes Vessel adequate, but trays

must be replaced with high capacity trays. Desorbent Stripper No Vessel inadequate

Extract Column Yes Vessel adequate. Replace existing trays with high capacity trays

Pacol & Define Adequate (Yes/No) Comments

Charge Heater Yes Replace existing burners

Pacol Reactor Yes Keep reactor shell. Modify internals to increase catalyst volume. New catalyst batch size will be 7.68 MT (9.1 m3) against the current batch size of 5.25 MT.

DeFine Reactor Yes No change

Product Stripper Yes Vessel adequate. Replace bottoms section trays.

Combined Feed Exchanger

Yes Pressure drop across spray bar is high. Replace the spray bar distributor.

Recycle Gas Compressor Yes Keep compressor. Replace gear box to meet minimum H2/HC ratio of 4.0 in PACOL reactor.

PEP Adequate (Yes/No) Comments

Adsorbers Yes No changes

Desorbent Column Yes No changes

Depentanizer Yes No changes

Detal Adequate (Yes/No) Comments

Reactors No Add 2500 spool piece to top bed of each reactor. LHSV inadequate to meet target linearity and catalyst life expectations.

Benzene Column Yes Implement new benzene flow scheme. Keep shell. Replace trays with high capacity trays in required sections.

Recycle Paraffin Column Yes Keep shell and trays. Replace packing in contact condenser section.

Paraffin Column Yes Keep shell and trays. Packing should be reviewed

LAB Column Yes Contact condenser requires new packing

Finishing Column Yes No change

Hot Oil section Adequate (Yes/No) Comments

All equipments Yes No change

NBA - Project Description As a part of integrating its Petrochemicals value chain, IOCL intends to install an integrated complex comprising of Acrylic Acid (AA), Synthesis Gas, Oxo Alcohol (Normal Butanol) and Butyl Acrylate (BA) Units based on propylene potential from its various refineries, such as Gujarat and Mathura.The basic objective of the Acrylics Oxo project is the installation of new Butyl Acrylate production facility consisting of installation of (i) Oxo Alcohol unit (90kTA of Normal Butanol), (ii) Modification of existing HGU-II unit at Gujarat Refinery to produce 8500 Nm3/hr of Syn. Gas and 4300 Nm3/hr of Hydrogen inside Gujarat refinery premises along with installation of (iii) Acrylic acid unit (90 kTA) & (IV) Butyl Acrylate unit (150 kTA) at Dumad near Gujarat Refinery. Propylene is raw material to Normal Butanol unit at Gujarat refinery & Acrylic acid unit at Dumad. Out of total 120 kTA propylene requirement for the project, 75 kTA Propylene will be available from PRU Unit proposed at Gujarat refinery under the J-18 capacity expansion projectBalance quantity will be met by propylene tankers from IOCL Mathura refinery for which unloading & storage system is envisaged at Dumad. Normal Butanol will be produced from Propylene, Syn Gas & Hydrogen and Acrylic Acid will be produced from Propylene. Normal Butanol and Acrylic Acid will be utilized for production of Butyl Acrylate. Units at Gujarat Refinery: (i) Synthesis Gas Unit: Modification of existing HGU-II unit at Gujarat Refinery has been envisaged to produce Syn Gas (capacity=8500 Nm3/h) and Hydrogen (capacity=4300 Nm3/h), the key raw materials for production of Oxo Alcohol. The unit is designed to process both Naphtha / Natural gas feedstock depending on availability. (ii) Normal Butanol Unit: A new Oxo Alcohol Unit with capacity to produce 90 KTA Normal-Butanol (NBA), a major feedstock for Butyl Acrylate production, has been considered. Oxo unit utilizes propylene and Syn gas as feedstock. Iso-butanol (~2.57 KTA) is a byproduct from the Unit and is intended for merchant sale.

Units at Dumad: (i) Acrylic Acid Unit: Propylene from Mathura and Gujarat refinery along with air is the major feedstocks for the Acrylic Acid unit (90 KTA capacity). Acrylic acid is produced by oxidation of

propylene in presence of oxidation catalyst. (ii) Butyl Acrylate unit: NBA and Acrylic Acid undergo esterification in BA Unit (150 KTA capacity) to produce Butyl Acrylate, the main product from the project.

Following project configuration has been considered for the proje

Conclusion: Gujarat Refinery, IOCL received EC form MoEF dated 14.07.2020 for J-18/LAB Revamp/N-Butanol project. Subsequently considering the change in product demand scenario in market and for optimization of project cost/economics, J-18 Project was revisited and after requisite value addition by inclusion of petrochemicals and specialty products (Lubes), the overall economic viability of the project was made better through modification in project configuration and product profile. Accordingly fresh EC application under modernization category is being submitted online for this modified project. However, through the analysis of the above feasibility reports of the three projects, it can be concluded that there will not be any incremental change in pollution load or resource depletion as compared to earlier projects for which approved EC had already been granted to Gujarat Refinery.

Attachment 1 Overall BFD 077154C-000-RT-0008-005_0

LUPECH PROJECT - BLOCK FLOW DIAGRAM

EXISTING UNITS (NOT AFFECTED BY LUPECH

AU-I PROJECT)

2000 KTPA

FPU-II

3000 KTPA

AU-II 2200 KTPA

VDU

1200 KTPA

AU-III 2700 KTPA

FPU-I

2400 KTPA

AU-IV 3800 KTPA

SR VGO

SR LPG

SR NAPTHA

AU-V

7300 KTPA

New Indmax

VDU SR VGO FCC 2700 KTPA

2500 KTPA

HCU

ATF/SKO

Revamp 1550 KTPA

DIESEL

LOBS

(CDW/HDF) LOBS

270 KTPA

LPG POOL

CRUDE

SR LPG LIGHT NAPTHA NHT 65 KTPA 360 KTPA

ISOM

360 KTPA

BS VI

GASOLINE

BLEND

NSU HEAVY NAPTHA

HEAVY

800 KTPA NAPTHA

MS BLOCK

CR LPGTU

PRU

580 KTPA

PPU

500 KTPA

POLY-

PROPYLENE

Octamax

110 KTPA

FCC GASOLINE BS-VI FCC GDS

Revamp

ARU

350 TPH

SRU

400 TPD

SULFUR

SWS

330 TPH

INDMAX FCC

SULFUR BLOCK


ATTACHMENT - 2

BLOCK FLOW DIAGRAMS / PROCESS DESCRIPTION

2. Process Units

2.1 AU-V Revamp

The existing atmospheric unit (AU-5) of Gujarat Refinery is designed to process 3.0 MMTPA of Arab mix crude. The unit consists of pre heat train on the upstream and downstream of desalters which are operating in series. The capacity of the existing crude preheat train is 375 MT/ hr.

The crude gets heated to a temperature of 290°C in the pre heat train before entering the Charge heater (Furnace) where it is further heated to the required temperature at the inlet of Atmospheric Distillation Column (Main Fractionation column). In the existing configuration, there is no Pre-topping column.

The main atmospheric (fractionator) column has three numbers of circulating reflux viz. as following which are withdrawn from product draw trays and circulated back to the column after exchanging the heat with the feed crude in the crude pre heat train.

Top CR Kerosene / ATF CR Gas oil CR

Three numbers of side strippers are provided to achieve the desired product profile from the main fractionation column as described here under.

Heavy Naphtha Stripper Kerosene Stripper Gas oil stripper

Stripper steam is injected in the column bottom and side strippers. The main column separates the preheated crude into the following products.

Un stabilized Naphtha Heavy Naphtha Kerosene / ATF Gas Oil RCO

Revamp Configuration The existing atmospheric unit (AU-5) is now being considered for capacity up gradation from 3.0 MMTPA to 7.30 MMTPA. The revamp configuration envisages the following:

Addition of parallel crude preheats trains before and after desalter for handling additional quantity of crude

FCCU old main fractionator (820-C-01) as pre-topper as desired by Gujarat Refinery (JR)

Reuse of maximum number of available equipment in order to limit the investment costs


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Change of some of the internals of main fractionator column and stabilizer column

Addition of new furnace in parallel to existing furnace. Two new side cuts i.e. Kero-1 and LGO are introduced in main column. The

existing Kerosene is termed as Kerosene-2 and Gas oil as HGO New side strippers are considered for Kero-1 and LGO. Existing 3 nos. of

strippers have been deployed for Heavy Naphtha, Kero-2 and HGO. Additionally, two nos. of circulating reflux i.e. Kero-2 CR and HGO CR are

provided to the main column to maximize the heat recovery and to balance the tower loads.

RCO flow split (LR-1 & LR-2) are to be considered. Pre-topper overhead air fin coolers and trim condensers are to be considered. Augmentation of OVHD condensers for main column by addition of parallel Air

fin coolers. De-bottlenecking of the existing pumps and additional pumps to be

considered wherever required. Additional product coolers for handling higher capacity. Provision for the draw-off (HHGO)of heavy gas oil cut in future. Provision for Coalescer + Salt dryer - for Kero-2. Provision to be kept for backing sweet fuel gas intoI column overheads.

Diagram 6.1a – Block Diagram of AU-5


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Diagram 6.1b – Block Diagram of AU-5

2.2 New Vacuum Distillation Unit (VDU)

A new VDU of 2.5MMTPA is envisaged as part of Lupech project. A simple process description of this unit is provided below.

Reduced crude from AU-V revamp is received in the Feed Surge Drum from proposed AU-V revamp unit and intermediate storage tanks. RCO will be received as cold feed from storage tanks and also as hot feed directly from atmospheric units. RCO is fed from storage tanks by offsite feed pumps to surge drum on level control. Feed surge drum pressure is maintained by pressure controller working on two control valves on split control. When the pressure reduces fuel gas lines opens, admitting gas into the surge drum and when pressure increase flare line opens setting down pressure to flare, through flare K.O. drum.

RCO is pumped from surge drum and preheated by heat exchange with vacuum diesel product, LVGO, HVGO & slop product and pumparound, Vacuum Residue and quench in a train of exchangers. HSD product and pumparound exchanger is to be bypassed for preheating RCO during hot feed case.

After getting preheated in the product & pumparound exchangers RCO mixes with Slop recycle and enters the four parallel passes of vacuum furnace under individual pass flow control. It is partially vaporized by further heating in the vacuum furnace before entering the flash zone of


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the vacuum column. Medium Pressure Steam is introduced into the individual heater passes to maintain requisite velocities and prevent coking due to high coil outlet temperature. The heater can be fired with fuel oil, fuel gas or combination of both. A temperature controller (TC) on combined furnace outlet controls the coil outlet temperatures (COT) to achieve desired vaporization of RCO by regulating fuel oil/ fuel gas flow to the burners. Vacuum Furnace is provided with an Air Preheater, to improve the furnace efficiency along with the FD fans and one ID fan.

Vacuum Distillation

In the bottom section of the vacuum column superheated LP steam is fed under flow control which lowers the hydrocarbon partial pressure and increases the vaporization in flash zone. This steam also results in desired stripping of liquid portion of feed below flash zone. Vapourized fraction of the feed and steam vapour rise through the upper section of the column and fractionated into four side products.

Vacuum column consists of 6 packed beds namely HSD Reflux bed, Internal Reflux bed, LVGO PA bed, HVGO PA bed, and two wash zone beds, 5 chimney trays above the flash zone and 4 stripping trays below the flash zone.

370 °c (-) diesel (HSD) is obtained as top side draw product from the chimney tray below HSD reflux bed. Top reflux and HSD internal reflux are drawn at the same point. HSD IR is sent under flow control to internal reflux bed. HSD product and pumparound exchanges heat with RCO in exchanger and is further cooled by circulating cooling water. Part of the stream is returned to the top of the column under flow control as reflux and the balance is sent to HSD or LOO tanks under level control of draw off chimney tray.

HSD product and pumparound drawn from the top side draw bypasses the RCO preheat exchanger during hot feed case. HSD product & pumparound rejects heat to circulating cooling water in exchanger alone during hot feed case. Gas oil internal reflux is drawn from chimney tray below internal reflux bed and pumped under tray level control to LVGO section.

Light Vacuum Gas Oil (LVGO) is obtained as second side draw product below the LVGO PA bed along with the LVGO pumparound and internal reflux streams. VGO IR is sent to HVGO section under flow control. The LVGO product and pump around exchanges heat with the RCO. LVGO pumparound is refluxed back to the column under flow control. LVGO product is further cooled in an Air fin cooler and a cooling water cooler and is sent to FCC feed storage under LVGO draw-off tray level control. A provision is kept to route hot LVGO from upstream of cooling water cooler to FCC unit along with Heavy Vacuum Gas oil.

Heavy vacuum Gas oil (HVGO) is obtained as 3rd side draw product below the HVGO PA bed along with HVGO CR and IR. HVGO IR is sent under flow control to wash section. Primarily HVGO product and CR exchange heat with RCO. HVGO CR is returned back to the column under flow control. HVGO product after exchanging heat with RCO, is used to generate MP & LP-steam. It is cooled further in the air fin cooler and Tempered water cooler arranged in parallel before being sent to FCC unit or FCC feed storage tanks under HVGO draw off tray


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level control along with LVGO. A provision is kept to route hot HVGO to FCC.

Slop distillate is drawn as the fourth side draw product below the wash zone beds into Slop Drum along with slop pumparound and recycle streams. Slop recycle under flow control, is mixed with RCO at the entry of the vacuum furnace. The slop distillate and pumparound exchange heat with RCO. Slop pump around stream is returned back under flow control to the column above the wash zone bed. Slop distillate mixes with vacuum residue downstream is used to generate M.P. steam and LP steam in heat exchangers. It is cooled further in BFW preheater and tempered water cooler before finally being sent to storage.

Alternatively slop distillate can be cooled separately in heat exchanger by circulating tempered water and routed to VBU Feed/LSHS/Slop storage tanks.

Vacuum Residue (VR) is drawn at the bottom of the column along with quench. Vacuum residue along with quench stream exchanges heat with RCO and is then used to generate MP steam. Quench is returned to the bottom of the column under flow control. The balance vacuum residue stream drawn under column bottom level control then mixes with slop distillate and the combined stream generate MP steam & LP steam before being cooled in BFW preheat exchanger and Tempered water cooler.

Vacuum overhead System

A multi stage ejector system with inter and after condenser, are provided to obtain the desired vacuum. The non condensables, cracked gases, inerts steam and a small amount of oil which might get carried over constitute the overhead vapors from vacuum column. The steam and oil are condensed in overhead condensers and collected in the Vacuum Condensate Drum. The oil is pumped intermittently to the slop oil coalescer by Slop oil pump which operates automatically with high and low level switches and is sent to HSD/Slop Header. The sour water is pumped continuously under level control and is routed to the sour water stripper system. The non-condensable are sent to vacuum furnace LP burners via Hot well catch pot. An inert recycle from 2nd stage condenser is provided to control the column overhead pressure.

The ejector motive steam may be adjusted by a pressure controller while the ejector elements, sized for 1/7th, 2/7th and 4/7th of total feed may be taken on line in different combination to achieve the desired vacuum.

Diagram 6.2 – Block Diagram of New VDU


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Neutralization facilities are provided to combat the stress corrosion cracking of Austentic stainless steel due to chloride and polythionic attack to heater tubes and transfer lines upto the last bend near the column, which are of solid SS-316 L material. Pure nitrogen is used to prevent the ingress of air into the system while it contains moisture, which forms polythionic acid on the surface when the system is cooled during shutdown or decoking of heater passes. Subsequently soda ash solution is passed through the system to neutralize any polythionic acid formed on the surface during shut down. Neutralization for the vacuum column, slop drums are optional as these are of material CS with SS316 L cladding and any cracks on the clad material tend to follow the clad interface rather than propagate into the pressure retaining backing.

Decoking facility for vacuum heater is provided during shutdown. Decoking pot had been designed for decoking one pass at a time. When one pass is being decoked, cooling steam is sent through the remaining passes.

2.3 SR LPG Treater

A new SR LPGTU of 65 KTPA is envisaged as part of Lupech project. SR LPGTU process converts mercaptans present in feed to H2S and removes it in Amine treatment and caustic treatment sections. LPGTU process sections are discussed below

Feed receiving section

It primarily consists of Feed filter, Feed Coalescer & feed surge drum. The feed is sent to filter to remove the debris or foreign particles. Filter outlet sent to feed coalescer to remove any entrained water in the feed and after that it sent to feed surge drum. It acts as just storage vessel. Sour water that gets collected in boot sent to CBD (Closed blow down).

Feed preheat section

In this section feed from surge drum sent to different heat exchangers to increase the feed temperature by utilising the heat of reactor effluent. In this sequence feed from surge drum is first sent to feed/reactor effluent heat exchanger via feed pump. Feed enters to shell side of exchanger and reactor effluent to tube side of exchanger and feed temperature increases from 40oC to 109oC. Exchanger outlet then mixes with hydrogen stream and mixed stream enters to tube side of HP steam heater. Hydrogen flow is controlled by feed flow. HP steam enters to shell side of HP steam heater and condensate sent to HP condensate drum, from where it goes to HP condensate header. Tube side outlet sent to reactor at 200oC. Reactor inlet temperature is controlled by HP steam flow. Electric heater is used only during startup and sulfiding process so HP steam heater outlet bypasses the electric heater and directly enters to the reactor. Main purpose of reactor is to convert mercaptans present in feed to hydrogen sulphide H2S at 200oC (SOR) and 27 kg/cm2g. Hydro treating reacting reaction slightly exothermic which increases temperature by 2oC only.

Reactor effluent cooling & separator section


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This section consists different exchangers like feed/reactor effluent heat exchanger, air fin cooler and cooling water exchanger. Reactor outlet sent to heat exchanger where it cools down up to 130oC and sent to air fin cooler to bring temperature down up to 65oC and finally sent to cooling water exchanger where temperature brought down to 40oC. Cooling water exchanger outlet sent to 3 phase HP separator from where sour water sent to CBD and liquid feed sent to Amine absorption column.

Amine treatment section

The feed is sent to the amine absorber where it is MDEA solution (28% concentration) fed to the top of column via amine booster pump. Lean amine flows in ratio control with column feed, it absorbs H2S present in feed and leaves column bottom as rich amine. Rich amine from column bottom sent to amine break vessel, to remove any entrapped hydrocarbon to sour flare and remaining rich amine sent to ARU (amine regeneration unit) for regeneration. Treated amine leaves the column as column overhead carrying some of lean amine and fed to sweet LPG coalescer to remove carried over amine from treated LPG. In this process column overhead mixes with DM water via DM water pump in static mixer and sent to sweet LPG coalescer, where water carrying amine sent to Amine blow down (ABD) on requirement basis and DM water circulation maintained.

Caustic treatment & product distribution section

The treated LPG from sweet LPG coalescer is sent to static mixer where it mixes with caustic (20% concentration) via caustic circulation pump. Mixed stream sent to the caustic vessel to remove H2S further from treated LPG. Lean amine flows in ratio control with column feed, it absorbs H2S present in feed and leaves column bottom as rich amine. Rich amine from column bottom sent to amine break vessel to remove any entrapped hydrocarbon to sour flare and remaining rich amine sent to ARU (amine regeneration unit) for regeneration. Treated amine leaves the column as column overhead carrying some of lean amine and fed to sweet LPG coalescer to remove carried over amine from treated LPG. In this process column overhead mixes with DM water via DM water pump in static mixer and sent to sweet LPG coalescer, where water carrying amine sent to Amine blow down (ABD) on requirement basis and DM water circulation maintained. The block diagram of SR LPG treater is presented in Diagram 6.5 below:


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Diagram 6.3 – SR LPG Treater Block Diagram

2.4 INDMAX RFCC

The primary objective of this Indmax RFCC unit is to maximize the production of propylene on fresh feed basis. The design feed rate for this Indmax RFCC unit is 2.7 MMTPA (Million Metric Tons per Annum). The on-stream run time per year is 8000 hours.

Indmax FCC unit consists of following major process blocks.

Reactor & Regenerator section - Reactor - Regenerator - Main air Blower - Flue gas desulfurization - Catalyst handling

Vapor recovery section - Main Fractionator - Wet Gas Compression - Primary and Secondary Absorber - Deethaniser Stripper and Debutanizer - LPG & Off gas treatment

The block flow diagram of each section is provided below. See process description 6.3.1 for more details.


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DIAGRAM 6.4 Reactor and Regenerator Section Flow Diagram

Diagram 6.5: Main Fractionator


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Diagram 6.6: Wet Gas Compressor

Diagram 6.7: Primary and Secondary Absorber


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Diagram 6.8 : Deethanizer Stripper and Debutanizer


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2.5 PRU

The objective of the Propylene Recovery Unit (PRU) is to recover the Propylene from LPG and supply downstream users with polymer-grade propylene for petrochemical applications.

To meet polymer-grade specifications, the stream should be concentrated to 99.5 % propylene and be essentially free of all relevant contaminants / impurities.

With Propylene Recovery Configuration, feed would first be de-butanized then de- ethanized. Thereaft

Date post:	09-Feb-2021
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