IOCL-PANIPAT REFINERY

Industrial visit started with a 40 minutes initial round of explanation by a senior engineer in the refinery. There was a questionnaire session in which students asked various questions about the processes, products, catalyst used in the refinery etc. Our questions were answered with proper reasoning. The second stage was a visit to the control room and look around to different sections of the refinery in which we visited various locations of refinery. INTRODUCTION:

Panipat Refinery, the 7th Refinery of Indian Oil, a Global Fortune 500 company having vision to become a major, diversified, transnational, integrated energy company, with national leadership and a strong environment conscience, playing national role in oil security & public distribution. Which is backed by global, state-of-the art technologies from Axens; France, Haldor-Topsoe; Denmark, UOP; USA, Stone & Webster; USA and Delta Hudson-Canada, DuPont, USA and ABB Luumas. Panipat Refinery is referred to as the countrys technically advanced refinery. 6 MMTPA refinery was built and commissioned in 1998 at a cost of Rs. 3868 Crore (includes Marketing & Pipelines installation). Refinery capacity has been further augmented to 12 MMTPA in June 2006 at a cost of Rs. 4165 crore. It receives crude oil from Vadinar and Mundra Ports in Gujarat coast. The refinery is designed for processing both indigenous & imported crude oil. The refinery has processed about 30 types of imported crude oil from countries like Saudi Arabia, Iran, Iraq, Dubai, Kuwait, Malaysia, Nigeria and other African countries since commissioning. Refinery has also ventured into petrochemical production with the commissioning of PX-PTA Units in June 2006 at a cost of Rs. 4228 crore. With this refinery will produce 3,57,000 MT/annum Paraxylene and 5,53,000 MT/annum PTA from the complex. PTA is the basic raw material for producing Polyester Staple Fibre (PSF), Polyester Filament Yarn (PFY) and other resins. PTA is produced from Paraxylene, One of the by products from the complex is Benzene of 21,000 tonnes per annum. Process Refinery unit (Commissioned in 1998)

PROCESS UNITS AVU Hydrocracker

LICENSOR / DESIGN

CAPACITY 6.0 MMTPA 1.7 MMTPA 38000 MTPA 0.7 MMTPA 0.7 MMTPA 0.5 MMTPA 0.4 MMTPA 0.5 MMTPA 2 X 115 MTPD CAPACITY

EIL, India UOP, USA HALDER TOPSOE, Hydrogen Unit Denmark Diesel Hydro- desulphurisation Unit IFP, France Resid Fluidised Catalytic Cracking unit Stone & Webster, USA Continuous Catalytic Cracking unit IFP, France Visbreaker unit EIL, India Bitumen Blowing Unit EIL, India Sulphur Recovery Unit Delta Hudson, Canada
Process units under Expansion Project (Commissioned in 2006)

LICENSOR / DESIGN

UNIT/AREA AVU Hydrocracker Delayed Coker Unit Coker LPG Merox Hydrogen Unit Diesel Hydrotreater Unit Sulphur Recovery Unit With Tail Gas Treating Unit Amine Recovery Unit

EIL, India UOP, USA ABB Lummus, USA UOP, USA HALDER TOPSOE, Denmark. IFP, France Black and Veatch, USA Black and Veatch, USA

6.0 MMTPA 1.7 MMTPA 2.4 MMTPA 0.1 MMTPA 2X70000 MTPA 3.5 MMTPA 2X225 MTPD 520 M3/Hr

Process units under Expansion Project (Commissioned in 2006)

CAPACITY(TPA) UNIT Naphtha hydro-treating & Continuous 500,000 catalyast Reforming Xylene fractionation unit 481,700 Shell Sulfolane extraction unit 152,200 Benzene Toluene fractionation 379,800 Paraxylene recovery unit(PAREX) 2,025,400 Isomerisation unit (Isomar) 1,656,500 Trans alkylation Disproportionation unit 360,200 (Tatoray)
LEARNINGS: Products from Refinery: With the expansion of Panipat Refinery to 12.0 MMTPA total high speed diesel produced from entire refinery will meet BS-II and BS-III Grade required for NCR. After stabilisation of units, the high value product yield from the refinery will be further improved by reducing the production of black oil like HPS and Bitumen. With state-of the-art matching secondary processing facilities was approved at a cost of Rs.4165 crore.

Products Crude oil LPG MS Naphtha SKO/ATF/MTO Diesel Bitumen Sulphur Coke

TMT 12000 444 900 847 1496 6117 150 156 700

Petroleum products are transported through Pipeline, Rail and Road. Majority of products would be transported

through environment-friendly pipelines. Panipat Refinery meets the demand of petroleum products not only of Haryana but also of the entire North-West Region including Punjab, J&K, Himachal, Chandigarh, Uttaranchal state and parts of Rajasthan & Delhi. LPG from the refinery is pumped through a dedicated pipeline to Kohand Bottling plant and bottling and bulk dispatches are done from there. Refinery Performance:

The Refinery has been increasing its capacity utilization since inception. Refinery has developed new products like 96 RON gasoline, sub-Zero diesel for the Indian army, and different grades of petrol, diesel & HPS for specific consumers. The refinery has started production of BS-II and Euro-III grade diesel and petrol since January, 2005. Refinery has started production of PTA since June 2006.

NAPHTHA CRACKER COMPLEX Indianoil with its long term plans to convert Panipat Refinery Complex into a central hub of its operations, has decided to put up Naphtha cracker & downstream polymer units (Naphtha Cracker complex) at Panipat. After storming into the field of petrochemicals with the PX-PTA project, Panipat Refinery is now consolidating its position in this sector by setting up of Naphtha Cracker Complex with an estimated capital investment of about Rs. 12000 crore. The site finalized for the project is near village Baljatan, which is on the southern side of the existing Panipat Refinery Complex. The Naphtha Cracker complex is scheduled for commissioning by mid 2009. This project aims at utilizing the surplus Naphtha available from IOCL refineries and creating valuable polymer products and other key intermediates. The Naphtha Cracker Complex will consist of a World scale Naphtha Cracker Unit and its Downstream Polymer units. Units under Naphtha Cracker Complex

Capacity (TPA) Units Naphtha Cracker LLDPE/HDPE Swing Dedicated HDPE Polypropylene MEG 800 (Ethylene) 350 300 600 300

ABB Lummus Global, USA has been chosen as the licensor for the Naphtha Cracker Unit. The primary

feed for Naphtha Cracker Unit is Naphtha, which will be thermally cracked to produce polymer grade ethylene and propylene, which will then undergo processing in downstream units such as LLDPE, HDPE, Polypropylene as well as key intermediates such as Butadiene, Mono Ethyl Glycol and Benzene. These products find application in a wide range of end usage. End use of Petrochemical products

Polymers

End Use

Polyethylene Ethylene glycol Polypropylene Polybutadiene

Films, bags, sacks, bottles and containers, wires and cables, house ware, flexible pipes, thermoware, toys etc. Polyester fibre, yarn, film, explosives, resins, printing ink, pesticides and insecticides, paints, varnishes etc. Tapes, sacks, yarn, pipes and sheets, film, medical use products, bottles, moulded luggage etc. Tyres, sports goods, footwear, rollers, battery boxes, gaskets, hoses, mechanical goods etc.

PTA and MEG are used for the production of Staple Fibre, Yarn, PET bottles, Tapes etc. The Naphtha Cracker complex along with the PX-PTA project will have synergic impact in the growth of downstream industries for the production of Polyester Staple Fibre (PSF), Polyester Filament Yarn (PFY) and Textiles. Based on the above raw material availability, there will be steady growth of related industries in this region and Panipat is going to develop into a world scale petrochemical hub of the country. The Hub will push Haryana to one of the top states in petrochemical production of the country.