PETROLEUM

INDUSTRIAL
CHEMISTRY
PROJECT

Haldia Petrochemicals Ltd (HPL)

NAME – Kartikeya Tiwari

ROLL NO. - 08BT01209

GROUP - B3
 INDEX

Sr. No. Topic Page no.

1. Abstract 3

2. Introduction 5

3. Products 9

4. Business Development 18

5 Figures (Illustrating Processes) 23

6 Conclusion, References 36-37

and Acknowledgement
 Abstract

Haldia Petrochemicals Limited | Email | Home

Haldia Petrochemicals Ltd (HPL)
Haldia Petrochemicals Ltd (HPL) is a competitive modern naphtha based Petrochemical Complex located
125 kms from Kolkata, at Haldia, West Bengal, India.

It is a prestigious Joint Venture project having the Government of West Bengal, The Chatterjee Group,
the TATAs with the Indian Oil Corporation, etc. as major stakeholders with an investment of Rs 5864
crores.

The complex consists of a naphtha cracker unit and associated plants which manufacture:

Linear Low Density Polyethylene (LLDPE)

High Density Polyethylene (HDPE)
Polypropylene (PP)
Benzene
Butadiene
Cyclopentane
C4 Hydrogenated (LPG)
Pyrolysis Gasoline (Py Gas)
Carbon Black Feedstock (CBFS)
Motor-Spirit

HPL is the second largest petrochemical industry in India with a total capacity equivalent to 5, 20,000
TPA of ethylene. Process technologies for various manufacturing plants have been selected from
internationally renowned vendors with an aim to produce world class products with excellent safety and
environment considerations. Notable process technology suppliers and contractors for the project
include -

Plant Technology Contractor

Naphtha Cracker Unit Lummus, USA Toyo Engineering, Japan
Butadiene Extraction Unit BASF, Germany Lurgi,  Germany
Benzene Extraction Unit Lurgi, Germany Lurgi,  Germany
Pyrolysis Gasoline Hydrogenation
Axens, France Lurgi,  Germany
Unit
C4 Hydrogenation Unit Axens, France SAIPEM, India
High Density Polyethylene Mitsui, Japan Daelim, South Korea
Linear Low Density Polyethylene Lyondell Basell, Netherlands Technimont, Italy
Polypropylene Lyondell Basell, Netherlands Daelim, South Korea
In 2007 turnover exceeded 2 billion USD and PAT reached its maximum, Rs 581 cr. The financial
indicators reflects sound health with expected Debt to Equity ratio at 1.10 at end of FY '08-'09
and Debt to Net Worth ratio expected to be strong at 0.75. Due to its strong financial
performance and commitments, recently, ICRA has assigned highest credit rating of 'A1+' for
the short term borrowing programs.
HPL are a customer focused organization, recognized as a leading supplier of quality products
and services.

A symbol of industrial resurgence in West Bengal, HPL has led the economic growth of the
region by propelling significant investments in downstream processing industries, which
generate huge employment opportunities for skilled and unskilled workers. Through strategic
market focus, innovative product application development and excellent customer support
services, HPL has played the role of a catalyst in emergence of more than 500 downstream
processing industries in West Bengal with a capacity to process more than 3,50,000 TPA of
polymers and generating more than 1,50,000 employment opportunities in the process. With
dedicated efforts, HPL truly symbolizes its motto –

"Come Grow With Us".

Introduction

Board of Directors

Name  
Mr Tarun Das Mr Pradip Roy
Chairman
Dr Purnendu Chatterjee Mr Atul Kumar Rai
Deputy Chairman
Mr Vijay K Chaudhry Dr Sabyasachi Sen, IAS
Mr Subhasendu Chatterjee Mr R Vasudevan, IAS (Retd.)
Mr Jamshyd N Godrej Mr Bhaskar Khulbe, IAS
Mr Sushil Muhnot Dr Subrata Gupta, IAS
Mr Sudesh Kumar Kapahi Mr Swapan Kumar Bhowmik
Managing Director
Ms Ramni Nirula  

Major Milestones

Year Key Events

2007 Turnover exceeded 2 Billion USD. Reported maximum PAT since
inception
2005 Capacity enhanced by 25%
2004 Reported PAT for the first time. Turnover exceeded 1 Billion USD
2003 Corporate Debt Restructuring (CDR) Approved
2001 Commercial production started.
2000 Project Commissioned. Trial production started
1997 Project construction started
1996 Land Acquisition completed
1994 MOU signed between WBIDC, Chatterjee Fund Management, Soros
Fund Management & Tata group of companies for implementation of
HPL Complex through a joint venture co.
1992 Environmental Clearance of the project received
1985 Incorporated as a public limited company

Financials

Performance of Haldia Petrochemicals Limited has been phenomenal since 2003-04.

Overcoming the past setback and backed by significant turnaround, HPL had posted its maiden
profit in 2003-04. During 2005-06, HPL wiped out all its accumulated losses and added Rs.
1,531.33 million to Reserves & Surplus and is standing at Rs. 7344.23 million as at March 31,
2007.

Backed by strong state-of-the-art technology, operating experience and committed efforts of

highly skilled manpower, the Company consistently operated its plant at rates higher than the
[declared] installed capacity. Naphtha Cracker capacity utilization during fiscal 2004-05, 2005-
06 & 2006-07 were about 104%, 103% and 106%.

In fiscal 2004-05, 2005-06 and 2006-07, the net sales (net of excise duty) of the Company were
Rs. 53,619.78 million, Rs.57518.70 million and Rs. 70873.70 million respectively, representing
about 32% increase from fiscal 2004-05 to fiscal 2006-07.

The quality of HPL’s products remained World Standard and continued to be appreciated in
domestic and international markets.

In 2006-07, polymers accounted for about 73% of the net sales as against 74% and 76% in
2005-06 and 2004-05 respectively. Chemicals accounted for about 27% of the turnover as
against 26% and 24% in 2005-06 and 2004-05 respectively.

Sales in the domestic market accounted for about 77% of the net sales in 2006-07 as against
75% and 67% in 2005-06 and 2004-05 respectively while the export sales accounted for 23% as
against 25% and 33% in 2005-06 and 2004-05 respectively.
Interest and financial charges reduced to Rs. 3,980.98 million in 2004-05 from Rs. 4,303.89
million in 2003-04 primarily due to implementation of CDR package. Interest expenditure
further reduced from Rs. 3304.56 million in 2005-06 to Rs. 2820.09 million in fiscal 2006-07 due
to prepayment of debts, refinancing of External Commercial Borrowings and repayment of
foreign currency debts.

During 2006-07, the Company recorded Profit Before Tax (PBT) of Rs. 8311.96 million, an
increase of 70% over 2005-06 of Rs. 4879.73 million and increase of 16% over 2004-05 of Rs.
7153.95 million.

The performance of HPL during the year ended March 31, 2007 is as under:

Net Sales – Rs. 70873.70 million

Operating Profit (EBITDA) – Rs. 14213.32 million
Interest & Financial Charges – Rs. 2820.09 million
Profit Before Taxation (PBT) - Rs. 8311.96 million

The Company is implementing expansion of capacity by about 30% which will take ethylene
production capacity to 670 KTPA from the current level of 520 KTPA.

The Company is firmly moving ahead and aims at growing aggressively.

Vision
To be a profitable, efficient and customer focused organization, recognized as a leading supplier
of quality products and services.
Delivering value to its shareholders.
Dedicated to achieve customer satisfaction.
Demanding, yet caring for its employees.
Demanding, yet fair and courteous to its vendors.
To be responsible as corporate citizen.

Corporate Social Responsibility

Being a responsible corporate citizen, HPL lays special emphasis on ensuring community welfare and
protection of environment. Since inception, HPL management through several initiatives has ensured
that harmonious relationship is maintained with the surrounding society and measures were taken to
improve the conditions of the deprived people. HPL social initiatives are focused towards –
Improving quality of life of displaced people
Sustainable skill development
Health & Community Welfare  
Educational & Social Causes
Environment Awareness & Protection.

Quality Policy

HPL is committed to total customer satisfaction; by delivering quality products and services
through continuous improvement of knowledge, skills, processes and involvement of all
employees and business associates.
 
Quality Management System in HPL

HPL is committed to customer satisfaction by delivering world class quality products and
services through customer focused product innovations, benchmarking and employing
standardized proven work practices. The entire business operations are certified to
international standard ISO 9001:2000 by DNV.

Energy Management System in HPL

HPL is committed to judicious use of energy for the production of quality goods & delivering
world-class services to the customers. We strongly commit HPLselves to sustainable
development by optimizing energy resources for efficient energy generation, energy
conservation and application of renewable energy.
The salient features of HPL Energy Management System are as follows :
Dedicated Energy Management Group to steer energy conservation activities.
Regular internal & external audits to identify and implement energy conservation measures.
Well-established training, awareness recognition programmes to enhance employee
involvement.
Products
Polyethylene

Haldia Petrochemicals Limited is the second largest manufacturer of polyethylene in India with a
total capacity of over 5, 00,000 tonnes per annum. It caters to more than 70% of the demand in
eastern India and 30% on overall country basis. The product portfolio under polyethylene
segment consists of various grades of High Density Polyethylene (HDPE) and Linear Low Density
Polyethylene (LLDPE).

HPL manufactures a wide range of HDPE grades having narrow, medium & broad (bi-modal)
molecular weight distribution using Mitsui Slurry CX Process to suit a wide range of end uses

HPL also manufacturers various grades of LLDPE in the swing LLDPE plant using Spherilene Gas
Phase Swing Process from Basell, Netherlands. The LLDPE plant is the 3rd such plant worldwide
using above technology and is used for manufacturing of various HDPE grades too.

These products from HPL are of benchmark quality, meeting the highest international standards
and are used extensively by packaging, consumer durables, houseware, automobiles, furniture,
container or luggage manufacturers in India and abroad. Due to superior quality, HPL products
are in demand in various countries from EU, South East Asia, USA etc. HPL products are exported
to more than 20 countries in the world.
Major Brands, Grades & End Uses

HDPE
Technology Partner – Mitsui, Japan

End Uses: Woven sacks; raschel bags for fruits & vegetables; containers for packaging edible
oil, processed food, FMCG, lubricants, detergents, chemicals, pesticides; industrial crates &
containers; carrier bags; houseware; ropes & twines; pipes for water supply, irrigation; process
industry & telecom.
Major grades under HDPE are –

HDPE  

Technology Partner – Mitsui, Japan

End Uses: Woven sacks; raschel bags for fruits & vegetables;
containers for packaging edible oil, processed food, FMCG, lubricants,
detergents, chemicals, pesticides; industrial crates & containers;
carrier bags; houseware; ropes & twines; pipes for water supply,
irrigation; process industry & telecom.
Major grades under HDPE are –

A: Mitsui CX Process

Category Grade MFI Density Major Applications Datasheet MSDS

F5400 0.09 0.954 General purpose film, Thin F5400.pdf HD.pdf
reinforced carry bags
HD T6 0.50 0.961 Lamination films, woven HD T6.pdf
Film
sacks and tarpaulin
F5001 1.1 0.950 General purpuse Film and F5001.pdf
extrusion.
Raffia R5801 0.50 0.961 Stretched tape/raffia for R5801.pdf
woven sacks and tarpaulin
Blow Molding B5500 0.40 0.956 Medium to large bulk B5500.pdf
containers for chemicals,
detergents or lube oil
B6401 0.40 0.964 Containers for lubricants B6401.pdf
and edible oil (up to 20 L)
 E5201 0.35 0.952 High ESCR blow-molding, E5201.pdf
cable sheathing and
jacketing, lamination and
general purpose film,
extrusion applications
E5201S 0.35 0.958 General purpose blow- E5201S.pdf
molding applications
Pipe P5300 0.25 0.948 PE 112 Pipe Applications P5300.pdf

  
 

Technology Partner – Basell

B: Spherilene Gas Phase Swing Process

Category Grade MFI Density Major Applications Datasheet MSDS

HDT10 1.1 0.950 Monofilament for net, HD T10.pdf HD.pdf
Mono- twines and ropes
filament HD T10S 1.1 0.950 Monofilament for net, HD T10S.pdf
twines and ropes
Raffia HD T9 1.1 0.950 Stretched tape/raffia for HD T9.pdf
woven sacks and tarpaulin
Injection M5018L 19.0 0.950 General purpose injection M5018L.pdf
Molding molded applications
M6007L 7.5 0.950 Injection molding of heavy M6007L.pdf
duty crates and industrial
products
M5025L 30.0 0.945 General purpose injection M5025L.pdf
molded applications
M6007LU7.5 0.950 Injection molding of heavy M6007LU.pdf
duty crates and industrial
products with UV
Stabilization
M5005L 4.5 0.950 Injection molding of heavy M5005L.pdf
duty crates and industrial
products
M5002L 2.5 0.950 Injection molding of Caps M5002L.pdf
 and Closures

  

LLDPE

Technology Partner – Spherilene , Basell

End Uses: General purpose packaging film, Rotomolded tanks, Drip

lateral, Extrusion-coating of woven fabrics and low voltage power
cables.

Major grades under LLDPE are –

A: Spherilene Gas Phase Process

Category Grade MFI Density Major Applications Datasheet MSDS

71601S 1.0 0.920 General purpose packaging 71601S.pdf  LLD.pdf
film, drip laterals
71601W 1.0 0.916 General purpose adhesive 71601W.pdf
lamination film
71602S 2.0 0.920 General purpose packaging 71602S.pdf
Film
film
71602W 2.5 0.916 General purpose packaging 71602W.pdf
film
71501S 1.0 0.920 General purpose packaging 71501S.pdf
film
Drip Lateral 71601D 1.0 0.920 Drip laterals 71601D.pdf
72307E 7.0 0.926 Extrusion coating of HDPE 72307E.pdf
Extrusion woven fabric, aluminum foil,
Coating jute, paper and allied
substrates
Roto-molding 73005T 5.0 0.934 Tanks and container for 73005T.pdf
domestic or industrial water
storage, sanitation,
agriculture
73005TU 5.0 0.934 UV stabilized tanks and 73005TU.pdf
 container for domestic or
industrial water storage,
sanitation, agriculture
73204T 5.0 0.932 Tanks and container for 73204T.pdf
domestic or industrial water
storage, sanitation,
agriculture
XLPE Silane LL T12 3.7 0.926 Low voltage power cable LL T12.pdf
Grafting insulation

Polypropylene

HPL manufactures more than 2, 75,000 tonnes polypropylene per annum using Spheripol-II
technology supplied by Basell, Netherlands. Spheripol process is the most widely accepted
technology for manufacturing Homopolymers and Copolymer grades. The unique process
capabilities and high consistency in product morphology ensure excellent quality.

These products from HPL are of benchmark quality, meeting the highest international standards
and are used extensively by packaging, consumer durables, houseware, furniture, container or
luggage manufacturers in India and abroad. Due to superior quality, HPL products are in
demand in various countries from EU, South East Asia, USA etc. HPL products are exported to
several countries in the world.
Major Brands, Grades & End Uses
PP

Technology Partner – Basell, Netherlands

End Uses: Woven sacks for cement, foodgrains, sugar, fertilizers; leno
bags for fruits & vegetables; TQ & BOPP films and containers for
packaging textiles, processed food, FMCG; office stationary; components
for automobile and consumer durables; molded furniture & luggage;
houseware; geotextiles; fibers for socks, sports wear; soft luggage.

Major grades under Polypropylene are –

A: Spheripol II Process

Category Grade MFI Density Major Applications Datasheet MSDS

 F103 3.0 0.90 BOPP Film Grade - General F103.pdf PP.pdf
Purpose, Lamination &
Metallizable films
R103 3.0 0.90 Raffia Tapes ,Woven Sacks R103.pdf
for Packaging Fertilizers,
Cement, Polymers, Carpet
Backing ,FIBC etc.
T103 3.0 0.90 Thermoformed Cups, T103.pdf
Homopolymer Containers & Other
- Extrusion disposable items
F110 11.0 0.90 TQ and Cast Films for F110.pdf
General Purpose Packaging
etc.
E116 16.0 0.90 General Purpose Extrusion E116.pdf
Coating
E125 25.0 0.90 Extrusion Coating of Woven E125.pdf
Fabrics etc.
M103 3.0 0.90 General Purpose Injection M103.pdf
Molding
M106 6.0 0.90 General Purpose Injection M106.pdf
Homopolymer Molding
– Injection
Molding M108 8.0 0.90 General Purpose Injection M108.pdf
Molding
M110 10.0 0.90 General Purpose Injection M110.pdf
Molding, Furniture etc.
Impact M304 3.5 0.90 Automotive Components, M304.pdf
Copolymer – Crates, Pails, Furniture etc.
Injection M310 10.0 0.90 Battery Boxes etc. M310.pdf
Molding M310S 10.0 0.90 Furniture, Pails, M310S.pdf
Compounding, Automotive
Components etc
M312 12.0 0.90 Compounding, Industrial M312.pdf
Components, Automotive
Components, Luggage, Pails,
Houseware, Sanitary Wares
etc.
M311T 10.0 0.90 Compounding, Automotive M311T.pdf
Components, Luggage and
Industrial Components
M325  25.0 0.90 Compounding, Automotive M325.pdf
 Components, Houseware,
Appliances parts, Extrusion
Coating
M340 40.0 0.90 Appliance & White Goods, M340.pdf
Automotive component,
Compounding,TWIM
B200 1.9 0.90 General Purpose Blow B200.pdf
Molded & Thermoformed
Items, Sheets for Files &
Random Folders.
Copolymer –
Blow Molding B202S 1.9 0.90 Bottle & Containers for B202S.pdf
Medical and Transparent
Products (e.g. IV Fluid
Bottles) etc

Motor Spirit Gasoline or Motor Spirit is a

petroleum-derived liquid mixture
consisting mostly of aliphatic
hydrocarbons and enhanced with
aromatic hydrocarbons toluene,
benzene or iso-octane to increase
octane ratings, primarily used as fuel
in internal combustion engines.

HPL makes Motor Spirit by adequate

blending of Hydrogeneted Pyrolysis
Gasoline with C5 and C6 raffinate.

HPL can produce 170 KTPA Motor Spirit in both as per Euro II & Euro III Standard Specifications.HPL
Motor Spirit Quality USP is :Motor Spirit is sold both in domestic markets mainly to Oil PSUs for and
private retailers and is exported to South East Asia, Africa & Mediterrenean Europe. HPL is all geared up
to produce the next grade of environment friendly low sulphur Motor Spirit as per Euro IV Standards.

Research Octane Number 92

High Purity, Low sulphur
Environment friendly as per Euro III Standards

Specifications   MSDS
C4 Hydrogenated (LPG)

Liquefied petroleum gas (also called LPG) is a mixture of hydrocarbon gases used as a fuel in
heating appliances and vehicles.

HPL produces 110 KTPA LPG through hydrogenenation C4 Raffinate by IFP technology, licenced
by IDEA, India. HPL LPG constitutes 100% Butane or Butane : Propane (90% : 10%) blend.

HPL LPG Quality USP :

Fully Saturated
Low Sulphur
High Octane

HPL sells LPG to both Oil PSUs and private retailers for sell in India. Major usage is in for
household supply for domestic cooking & heating and some portion also go for industrial fuel
usage. HPL is trying to make entry into HPL LPG usage in Auto-Fuel segment.

Specifications   MSDS

Pyrolysis Gasoline

Raw Pyrolysis Gasoline (RPG) aromatics-rich naphtha-range stream produced in sizeable

quantities by an ethylene plant when it cracks naphtha, butane or gasoil. Raw Pygas resembles
reformate. It can serve as a high-octane blendstock for motor gasoline or as a feedstock for an
aromatics extraction unit.

Hydrogeneted Pyrolysis Gasoline (HPG) obtained from RPG post Benzene extraction and is used
as chemical feedstock for Aromatics – Toluene, mix-Xylene and low & heavy grade Fuel Oil. It is
also used as gasoline blending component.
HPL HPG Quality USP is :
High Octane
Low Sulphur
Low Benzene

HPG is sold both in domestic markets mainly to Oil PSUs for gasoline blending and is exported
to South East Asia, Africa & Mediterrenean Europe. HPL is also promoting use of HPG as
chemical feedstock for value added extraction of chemicals - aromatics and fuel oil.

Specifications   MSDS

Carbon Black Feedstock (CBFS)

Carbon black feed stock (CBFS) is the heavy hydrocarbon mix (above C9
to C15) bottom product of Naphtha cracker unit. CBFS is the key raw
material used to manufacture carbon black. Roughly 2.2 tonnes of CBFS
is required to produce one tonne of carbon black. Carbon black is
basically used as a reinforcing agent in rubber products such as tyres,
tubes, conveyer belts, cables and other mechanical rubber goods.

CBFS is also used as heating Fuel Oil in several industrial units.

HPL can produce 54 KTPA of CBFS which is sold to both Carbon Black manufacturing and for fuel
oil usage.
HPL CBFS Quality USP :
Low heavy metals
Low sulphur
Awards & Achievements

HPL Achievements
Certification on ISO-14001 by M/s Det Norske Veritas, Netherlands.
Certification on OHSAS-18001 by M/s Det Norske Veritas, Netherlands.
British Safety Council's award of 5 STARS for Health & Safety Management
Systems.
Ranked first for its Safety Management by Confederation of Indian Industry
(CII), 2001-2002.
Ranked first for its excellent Environment & Safety Management by West
Bengal Pollution Control Board and Indian Chamber of Commerce, 2002-
2003.
ICMA (Indian Chemicals Manufacturers Association) Award 2002-03 for
Excellence in Management of Health/Safety/Environment.

Marketing Set Up

Polymers are marketed through HPL 4 Regional offices and 6 area offices across the country.
For details click on “Offices & Marketing Contacts”

Polymers
Linear Low Density Polyethylene (LLDPE)
High Density Polyethylene (HDPE)
Polypropylene (PP)

Chemicals
Benzene
Butadiene
Cyclopentane
C4 Hydrogenated (LPG)
Pyrolysis Gasoline (Py Gas)
Carbon Black Feedstock (CBFS)
Motor-Spirit
Business Development
Introduction
Business Development is of strategic importance to the growth of Haldia Petrochemicals
Limited. A dedicated team of professionals act as a strong arm of the marketing team in
developing plastic processing industry in West Bengal to promote HPL product consumption
within the region and generate employment and economic prosperity in the region.
 
Objectives
Increase PO consumption in West Bengal & Eastern India
Creation of Plastics Processing Capacity
HPL’s Support for setting up of plastics downstream units
Development of Clusters – a cost effective manufacturing hub
Facilitating development of skilled manpower
Catalytic role in enhancing Export of Plastic Processed Products
Creation of Employment opportunities
Plastics & Environment

 
What we offer to encourage growth in plastic downstream industries?

1. Developing new applications – Geotextiles, Leno Bag, Food Packaging Containers, Tea
Packaging, Rotomoulding and new market for the downstream industries
2. Support to the downstream processing industry by creating a wider market for their
products.
3. HPL identifies buyers, develops product along with the vendors and facilitates smooth
exports of plastics products.
4. Creating interest among investors about opportunities in plastics downstream industry
5. Direct Employment in the plastics processing industry
6. Significant indirect employment in transportation, casual work-force, infrastructure
development and maintenance in industrial areas (food outlets, shops, public vehicle etc.).

Customer Services & Application Research

Customer Services (CS) group is dedicated to HPL’s polymer business activities. CS provides
support and functions for continuous enhancement of customer satisfaction through polyolefin
product & application research. This is achieved by new product development and quality
enhancement of existing products for changing customer needs.
Customer Focus
Customer Services plays catalytic roles in developing new customers & markets for HPL products. The
activities of CS focus on:

Assisting customers for HPL grade selection

Extending technical support to customers
Providing processing guidelines and application related information
Providing testing and analytical support on raw materials and finished products
New product development and customization for specific market requirements
Conformance to statutory requirements for HPL products
Product positioning, trials and technical establishment
Monitoring customer feedback and optimization of product design

Customer Services functions as an interface between customers and the polyolefin

manufacturing plants. The CS group works in tandem with the customers to understand their
technical needs and help them achieve their business objectives with HPL’s products.
CS interacts with customers to anticipate their emerging needs and future market requirements
and initiates necessary measures for facing new challenges.
Customer Services plays a key role in defining HPL’s product quality. This is augmented with
periodic quality reviews and benchmarking.
Applied Research and Innovation
Since its inception CS has contributed to the growth of HPL by introducing, developing and
retaining world-class quality products in a competitive market.

CS activities in the domain of Applied Research in polyolefins are tuned to serve HPL’s long term
polymer business objectives. The research activities are guided by existing manufacturing
capacities and challenges in times to come.

The polymer product basket of HPL is a manifestation of the innovative instincts augmented by
rigorous evaluations and analytical initiatives of the CS team.

HPL polyolefin grades for the Indian and the Exports market:

Halene H (HDPE)
Halene P (PP)
Halene L (LLDPE)
The specialty products of HPL developed by CS group’s innovative ideas and efforts include
LLDPE grade for wire & cable applications, LLDPE drip lateral pipe grade,
No break PP impact copolymer grade, High MFI HDPE for Injection Molding, Hi MFI PP Impact
Copolymer for Compounding & Automotive applications, etc.

HPL enjoys major customer lock-in owing to the extensive support from CS. The sectors in
which ‘Brand Halene’ enjoys customer preference in the Indian and overseas markets include
HMHDPE film, HDPE Pipe, HDPE Blow Molding, PP Raffia, PP Thermoforming,
PP Impact Copolymers for furniture, battery, automobile & luggage sectors,
PP Random Copolymer for medical applications, HDPE Injection Molding, LLDPE
Rotomolding,BOPP & TQPP films.
Performance Additives – Developments and Collaborations
CS team is responsible for performance additives as part of polyolefin product design. HPL
polyolefin grades have been additivated to meet the processing as well as end use
requirements of target sectors. These are reviewed and modified to meet the changing market
needs of new processing machines and user preferences. CS ensures the additivation packages
are designed to meet world class product performance.

New generation additives are evaluated to add value to HPL products and provide the same to
the customers.
CS collaborates with world leaders in additives to build a synergistic relationship that ensures
that HPL products retain their edge over competitors. HPL has played key role in evaluating and
launching new products from additive suppliers of international repute.
Plastic Machinery Tie-ups
CS interacts and works closely with plastics processing machinery & mold manufacturers. This
exchange is focused towards the application areas and markets where HPL is currently present
as well as for future expansion options.
Leading Indian machinery manufacturers design and optimize their machine for throughput and
end product quality based on HPL polyolefins. This provides particular advantage to customers
adding new processing capacities and with plans to source raw materials from HPL
Knowledge Dissemination and Training Initiatives
Product Knowledge Programs are arranged by Customer Services to disseminate product
related information.
CS also organizes training programs for the benefit of plastic processing industries in bringing
new concepts, exhibition of new products, sharing knowledge of latest technologies,
development in plastics processing and applications.
Systems, Monitoring and Review
CS group has established quality management systems to measure, monitor and control quality
and its improvements. The performance of CS is continually assessed through SQC tools,
external and internal customer surveys, auditing and self assessments.
CS plans, performs and monitors its designated activities to conform to the organization’s
Integrated Management Systems in line with ISO 9001 standards.
Facilities – Testing and Analysis
CS is equipped with a world class analytical laboratory for customer support to aid end-use
development. The testing facilities include analysis of polyolefin properties covering areas like:
Polyolefin raw material:
  Melt behavior and Flow
  Density
  Mechanical
  Spectroscopy
Finished Products:
  Optical
  Mechanical
  Material identification
CS polyolefin processing facilities include:
  Twin-screw compounding
  Injection molding
  Blow Molding
  Blown film extrusion

Primary feedstock for HPL is Naphtha.

HPL consumes around 1.7 mmtpa of High Paraffinic Naphtha ( min 75% Paraffin and Max 6%
Aromatics, Max 500 ppm Sulphur ) in its naphtha cracker unit at full throughput . In addition
the complex also requires about 240,000 MT per annum of fuel grade Naphtha for use in their
Captive power plant.

Post expansion HPL's requirement for feed would be enhanced to 2.2 mmtpa of Feed and
300,000 MT of Fuel Naphtha.

HPL's suppliers include International and Domestic Oil Majors like KPC- Kuwait, ADNOC- Abu
Dhabi, BAPCO- Bahrain, Indian Oil Corporation, Bharat Petroleum etc as well as globally
renowned traders like Glencore, Shell, BP, Vitol etc.

Naphtha is purchased both through Long Term Contracts via direct negotiation as well as
through tender on Spot basis. Transportation of Feed Naphtha is through Clean Product
Tankers in Parcel size of 25,000 MT or 50,000 MT (after Ship To Ship transfer at Vizag) with the
cargos unloading at the adjacent Haldia Port.

Naphtha is stored at HPL’s plants in HPL storage tanks with a total capacity of around 120,000
MT which would go up to 150,000 MT post expansion. The tanks are connected to all the three
Oil Jetties at Haldia Ports through dedicated Pipelines.
Figures (Illustrating the processes)

Petroleum Refining- The Mother Industry

Transport
95%

Petroleum Petro
Energy
Refining chemicals

Chemicals
&
Fertilizers
Polymer Processes (Used globally)

Ethylene to Polyethylene High pressure tubular process

(LDPE) LDPE, LLDPE, HDPE Chevron-Phillips slurry process

Basell Spherilene process ( LLDPE/HDPE)

NOVA- Sclairtech process ( LLDPE/HDPE)

Propylene to Polypropylene Basell Spheripol PP process

PP, PE Copolymers Dow UNIPOL PP process

Borstar PP process
CONCLUSION
The Indian Plastics Industry is well set on a high growth path and this can be achieved only
by responsible participation of all the players in the Industry. HPL is a growth engine not only
for West Bengal but for the whole of India.

PLANT CAPACITIES
Plants Capacity Technology/Licensor
Nephtha Cracker (Ethylene) 420,000 TPA ABB Lummus, USA
PP 210,000 TPA Montell, Italy
LLDPE/HDPE (Swing) 225,000 TPA Montell, Italy
HDPE 200,000 TPA Mitsui, Japan
Butadiene 74,250 TPA BASF, Germany
Pyrolysis Gasoline Hydrogenation 117,400 TPA IFP, France
Benzene 77,050 TPA Lurgi, Germany

LSTK Constructors Units

Toyo Engineering Corporation,
Naphtha Cracker
Japan
Daelim Engineering Company,
PP
Korea
Daelim Engineering Company,
HDPE
Korea
Tecnimont, Italy LLDPE
Pyrolysis Gasoline
Lurgi, Germany
Hydrogenation
Lurgi, Germany Benzene Extraction
Lurgi, Germany Butadiene Extraction

Its acceptance of environment friendly and convenient energy policy it is able to save lot of commercial
savings.
ACKNOWLEDGEMENT
The given project report on Haldia Petrochemicals Limited was highly beneficial as it gave us an
idea of the first step in the downstream petroleum industry. It is very important for us to know
each of the process in details. I would like to thank Dr. Lalita Ladwani for giving us an
opportunity in making this project successful.

Besides I would like to thank my friends Jinendra Chopra, Bhavik Shah and Harsh Jain who had
helped me out in searching of various resources.

REFERENCES
Encyclopedia article

Wikipedia article

Pdfdatabase.com

http://www.HPL.com

10 th Orientation Course in Catalysis for Research Scholars (28 th November to 16 th December,2009)

Dr.K.R.Krishnamurthy, National Centre for Catalysis Research (NCCR-)Indian Institute of Technology
Chennai-600036-For the figures