FEASIBILITY REPORT FOR OXO- ALCOHOL/ACRYLICS...

FEASIBILITY REPORT FOR OXO-

ALCOHOL/ACRYLICS PROJECT

DESIGN BASIS (Option-d)

CONFIDENTIAL

42 SHEETS WITH COVER

D I S T R I .

IOCL 4

MHI 1

R E V I S I O N S

2 27Mar15 IOCL comments incorporated IOCL E-mail dated 01-Dec-14 ABU SBY VPS - - SBY

1 18Sep14 - - ABU SBY VPS - - SBY NO DATE DESCRIPTION REFERENCE APP’D APP’D

SECTION PROJECT TEAM ORDER NO. P115101

CUSTOMER:

Indian Oil Corporation Ltd.

PROJECT TEAM : APPROVED SBY PROJECT:

IOCL AA / OXO Value Engineering

SECTION PROCESS ENG’G GR. APPROVED VPS CHECKED SBY DOC . NO. :

MEIP-3977-B211-00120

REV.

2

PREPARED MHA ISSUE DATE 30-July-2014 TOTAL 5

MEIP

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SUMMARY OF REVISIONS (Revision number is shown as)

DOC. No. MEIP-3977-B211-00120

Cover Sheet Page No. of corresponds to associated revision

Original Revision

Remarks Rev. Date Rev. Description Rev. Description

0 30-Jul-14 Issued for Rev.0

1 18-Sep-14 1 Issued for Rev.1

2 27-Mar-15 5, 23, 30, 31, 38 2 Based on IOCL’s comments data are

updated

Issued for Rev.2

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Contents

Sl. No. Description Page No.

1 General ……………………………………………………………….. 04 2 Project Name and Location …………………………………………. 04 3 Definition of Battery Limits ………………………………………….. 04 4 Plant Design Capacity ………………………………………………. 04 5 Definition of Case Study …………………………………………….. 06 6 Area-Section Identification and Equipment Nomenclature ……… 07 7 Product Quality ………………………………………………………. 10 8 Raw Material Quality ………………………………………………… 12 9 Catalysts and Chemicals (Process Units) …………………………. 25

10 Product Storage Capacity …………………………………………… 30 11 List of new facilities for Utilities and Off-sites …………………….. 31 12 Product Evacuation …………………………………………... 32 13 Tie-in Points …………………………………………………………... 33 14 Plant and Non-Plant Building ……………………………………….. 34 15 Basis for Estimation …………………………………………………. 35 16 Material Classification for OXO, AA Process 36

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1. GENERAL

This design basis is prepared for Additional Feasibility Study (FS) to reflect the outcome & decisions taken during Value Engineering (VE) meeting held in Japan on 3rd & 4th Jul, 2014 for AA / OXO FS Project of Indian Oil Corporation Ltd. which intends to produce Butyl Acrylate as final product. The objective of the Additional feasibility study is to improve the project feasibility & profitability based on the project cost estimate with accuracy of ±30%.

2. PROJECT NAME AND LOCATION

Project Name : IOCL AA / OXO VALUE ENGINEERING Plant Name : ACRYLICS / OXOS Plant Location : GUJARAT, INDIA.

3. DEFINITION OF BATTERY LIMITS

Acrylics / OXO Plant means the Plant to produce Butanol and Butyl Acrylate by using the process technology licensed by Mitsubishi Chemical Corporation (hereinafter call “MCC” or LICENSER”) i.e. the Plant includes not only process units but also feedstock preparation units such as Syn. Gas Unit and necessary utility/off-site facilities which have been involved in Case-A(1) in the previous Feasibility Study Report submitted in December, 2013.

Process plants shall be part of “ISBL”. Utilities & all Off-sites facilities shall be part of “OSBL”.

4. PLANT DESIGN CAPACITY

4.1 Product Design Capacity Product design capacity and annual operation hours are as follows.

Products Design Capacity (kTA)

Operation Hours (per year)

Normal Butanol (NBA)

92.2 8,000

Iso Butanol (IBA)

8.8 8,000

Acrylic Acid (AA)

89 7,992

Butyl Acrylate (BA)

153 7,992

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4.2 Design Capacity of Syn Gas Unit

- Syn. Gas Production Capacity: Maximum 8,140 Nm3/h (as 100 mol% H2 +CO in dry) - Hydrogen Gas Production Capacity: Maximum 4,290 Nm3/h (as 100 mol% H2 )

Note : The above figures are corresponding to the new Syn Gas unit required for Integrated Acrylics / OXO project at Dumad.

4.3 Required Design Capacity of PRU Design Capacity: 121.7 kTA

For details, please refer PRU design basis document no. B211-00110-PRU Design Basis

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5. DEFINITION OF CASES FOR VALUE ENGINEERING

Value Engineering is done for the selected base configuration Option-d. Plant locations are same alike Case-A(1) of Feasibility study, however, process configuration is different.

Please see the below table for understanding of the Option-d:

DEFINITION OF DIFFERENT CASES FOR FEASIBILITY STUDY

CASE NAME

PROJECT SITE

DESCRIPTION

Option-d

Dumad, Gujarat

Integrated Acrylics/OXO Project and Syn. Gas Unit at Dumad (15km away from Gujarat refinery)

Option PRU

(kTA) Acrylic

Acid (AA) Unit

(kTA)

Glacial Acrylic

Acid (GAA) Unit

(kTA)

Butyl Acrylate

(BA) Unit

(kTA)

Oxo Alcohol (Oxo) Plant (kTA)

Normal-But anol (NBA)

Export (kTA)

Iso-Butanol (iBA)

Export (kTA)

(d) 121.7 89 0 153 101 0 8.8

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6. AREA-SECTION IDENTIFICATION AND EQUIPMENT NOMENCLATURE

A. Plant area number and section number for Production plants including Auxiliary systems are defined as below.

(1) Production Plant

Area Number

Section Number

Plant/Section (Unit) Name

IOCL to indicate

Total PRU(Propylene Recovery Unit) at Gujarat Refinery

3000

Syn Gas Unit

100 Desulphurization and Reforming Section

200 CO2 Removal and Recycle to Reforming section

300 Membrane Section 400

PSA Section

500

Compression Section

4000

OXO Plant

100 OXO Section

200 TOL Recovery & Heavy End Separation Section

500 NBA Section

600 IBA Section

5000

AA/BA Plant

100 AA Oxidation Section

200 AA Purification Section

400 BA Section

600 Waste Treatment Section

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(2) Auxiliary System and Facilities

Area Number

Section Number Plant/Section (Unit) Name

100 Water System (Cooling Water, Demi.Water, Industrial Water, Service water, Potable Water, Refrigerated Water, etc)

200 Steam Generation, Supply and Condensate System

7000 300 Plant Air & Instrument Air Supply, Nitrogen Supply System 400 Fire Fighting Facility & System

500 Natural Gas / Naphtha Supply System (for Syn Gas Unit) 600 Fuel Gas and Fuel Oil Supply System 700 Waste Water Treatment System, Off Gas and Flare System 800 Tank System, Products Lorry & Drum Filling Unit 900 CPP Unit

Note:

(1) Dumad: All the utility facilities shall be considered as new. New raw water pipeline from Mahi river to Dumad to be considered.

(2) Gujarat Refinery: All utilities required for PRU, propylene storage, naphtha and NG forwarding. For Dumad, 8-9 MW power may be available from Gujarat refinery. However, new CPP to be considered for Dumad and Koyali both locations. The existing raw water supply from Mahi river to refinery may be extended to the requirement of AA/ OXO plant at Koyali.

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B. EQUIPMENT NOMENCLATURE:

A Agitator B Boiler C Column D Drum E Heat Exchanger F Filter, Centrifuge, H Heater/Furnace, Tubular Reformer J Ejector K Compressor, Blower, Fan (Including drives) M Miscellaneous Items (Mixer, Hopper etc.) P Pump (Including drives) R Reactor T Tank U Kept for future

X

Process Package Items (e.g. Catalytic Recovery Unit)

Z

Utility & Off-site Package Items (e.g. N2 unit, Waste Water Treatment, Raw water Treatment Unit, DM Water Treatment Unit, Stack, Cooling Tower, Refrigerated Unit, Instrument Air Dryer, Incinerator, CPP Unit etc.)

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7. PRODUCT QUALITY

Qualities of products are specified as follows.

1) AA (Acrylic Acid)*1

Items Units Design Basis of Product Quality Purity wt.% Not less than 99.0 Water wt.% Not more than 0.1 Acetic Acid wt.% Not more than 0.08

Note *1: Acrylic Acid is used as raw material to produce GAA and BA.

2) BA (Butyl Acrylate)

Items

Units

Design Basis of Product Quality

Color APHA Not more than 10 Purity wt.% Not less than 99.0 Water wt.% Not more than 0.05 Free Acid

(as acrylic acid)

wt.ppm

Not more than 50

Inhibitor (as MQ)*1

wt.ppm

Not more than 20

Note *1: MQ(Hydroquinone Monomethyl Ether) is adjusted from 10 to 20 wt.ppm

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3) Normal Butanol (NBA)

Items

Units


Purity wt.% Minimum 99.8 Color APHA Maximum 5 Water wt.% Maximum 0.01 Aldehyde *1 wt.% Maximum 0.02 Acidity *2 wt.% Maximum 0.001 Sulphuric Acid test APHA Maximum 10 Specific Gravity(20/20 deg.C) 0.810 - 0.812 Distillation range deg. C 116 - 118

Notes *1: The figure is shown as Butyraldehyde. *2: The figure is shown as acetic acid.

4) Iso-Butanol (IBA)

Items

Units Design Basis of Product

Quality Purity wt.% Minimum 99.7 Color APHA Maximum 5 Water wt.% Maximum 0.01 Aldehyde *1 wt.% Maximum 0.02 Acidity *2 wt.% Maximum 0.001 Sulphuric Acid test APHA Maximum 10 Specific Gravity(20/20 deg.C) 0.802 - 0.804 Notes *1: The figure is shown as Butyraldehyde.

*2: The figure is shown as acetic acid.

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8. RAW MAT ERIAL QUALITY Stream Conditions & Flow rates of Raw Materials supplied from Owner’s existing facilities are specified as follows:

8.1 Propylene Recovery Unit

8.1.1 Feed for PRU @ Gujarat Refinery (Pre FCC Revamp): Please refer PRU design basis document no. B211_00110_PRU Design_Basis

8.1.2 Feed for PRU @ Gujarat Refinery (Post FCC Revamp): Please refer PRU design basis document no. B211_00110_PRU Design_Basis

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8.1.1 PRU Feed Stream Condition for AA/BA PRU @ Gujarat Refinery (Pre FCC Revamp)

Please refer PRU design basis document no. B211_00110_PRU Design_Basis

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Fig-8.1 Design Condition of AA/BA PRU @ Gujarat Refinery


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8.1.2 Feed Stream for PRU @ Gujarat Refinery (Post FCC Revamp)

Fig-8.2 Design Condition of Integrated Plant PRU @ Gujarat Refinery


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8.2 AA/BA Plant

1) Propylene(PPY)

Composition of Propylene fed to reaction unit is specified in Table 8.1.

Remarks : Conditions at inlet of the AA Unit; Flow : Expected: 7.65 t/h ( as 99.5 wt% C3 H8 ) Pressure : More than 16.0 kg/cm2(g) Temperature : Ambient Phase : Liquid state (delivered by pipeline)

2) N-Butanol

Items

Units


Purity wt.% Not less than 99.5 Appearance - Transparent (no visual impurity) Color APHA Not more than 10 Specific Gravity(20 deg.C) g/cm3 0.810 - 0.812 Acidity (as CH3 COOH) wt.% Not more than 0.003 Distillation range (at 0 deg.C, 101.3 kPa)

• Initial boiling point deg.C Not less than116.0 • Dry point deg.C Not more than119.0

Sulphuric acid wash color APHA Not more than 35 Water wt.% Not more than 0.4

Other impurities *1 wt.% Not more than 0.1 Notes *1: Key impurities: DiButyl ether, methyl Butanol and others

Remarks : Conditions at inlet of the BA Unit; Flow : Expected : 11.5 t/h ( as 99.5 wt% n-BuOH) Pressure : 1.0 kg/cm2(g) Temperature : Ambient Phase : Liquid state

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Table 8.1 Specification of Propylene (for AA/BA Plant)

Composition Design Basis of Product Quality Units

Propylene Not less than 99.5 wt % Propane Not more than 0.4 mol % Methyl acetylene Not more than 2 wt.ppm Propadiene Not more than 3 wt ppm Methane Not more than 200 vol.ppm Ethane Not more than 300 vol.ppm *1

Ethylene Not more than 10 wt.ppm Acetylene Not more than 1 wt.ppm 1,3-Butadiene Not more than 3 wt.ppm *2

Total C4 Not more than 10 wt.ppm Total C5 & heavier Not more than 10 wt.ppm Hydrogen Not more than 1 wt.ppm Carbon monoxide Not more than 0.03 wt.ppm Oxygen Not more than 1 wt.ppm COS Not more than 20 wt.ppb Carbon dioxide Not more than 1 wt.ppm Water Not more than 2 wt.ppm Ammonia Not more than 0.2 wt.ppm Total Sulfur as H2 S Not more than 0.5 wt.ppm Arsene Not more than 20 wt.ppb Phosphine Not more than 0.03 wt.ppm Methanol Not more than 5 wt.ppm Oxygenated solvents Not more than 10 wt.ppm *3

Note: *1 : This value may not be adopted depending on the local environmental regulation about non-methane

carbon in the process effluent gas from Catalytic Combustion Unit.

*2 : Butadiene expected to be Nil.

*3 : Methanol, ethanol, propanol, acetone, acetaldehyde.

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8.3 OXO Plant

1) Propylene(PPY) (1) Composition

Composition of Propylene fed to reaction unit is specified in Table 8.2.

(2) Flow : Normal : 7.56 t/h (as 100 % propylene) (3) State : liquid (4) Pressure : 25 kg/cm2(g) (5) Temperature : 40 deg.C

2) Syn Gas (GOX)

(1) Composition :

Composition of Syn-Gas fed to reaction unit is specified in Table 8.3.

(2) Flow : 8,140 Nm3/h ( as 100% CO + H2 ) (3) State : Gas (4) Pressure : Minimum 25 kg/cm2(g) (5) Temperature : 40 deg.C

3) Hydrogen Gas (GH) (1) Composition :

Composition of Hydrogen gas fed to reaction unit is specified in Table 8.4.

(2) Flow : 4,290 Nm3/h (as100% H2 ) (3) State : Gas (4) Pressure : Minimum 45 kg/cm2(g) (5) Temperature : 40 deg.C

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Table 8.2 Specification of Propylene (OXO Plant)

Composition Quality (limit value) Units Purity(as propylene) Minimum 99.5 mol % Propane(and Ethane) Maximum 0.5 mol % Ethylene Maximum 0.01 mol %

* Acetylene Maximum 1 mol ppm * Methyl acetylene Maximum 1 mol ppm * Propadiene Maximum 1 mol ppm * Butadiene Maximum 1 mol ppm

Total C4 s Olefine Maximum 0.01 mol % * Total C4 & C5 Di-Olefines Maximum 1 mol ppm * Total Oxygen Maximum 1 mol ppm * Total chloride (as HCl) Maximum 0.05 wt ppm * Total sulphur (as S) Maximum 0.1 wt ppm * - H2S Maximum 0.01 wt ppm * - Carbon sulphide Maximum 0.02 mol ppm * Total arsenic (as As) Maximum 0.01 wt ppm

Water Maximum 5 wt ppm * Green oil Maximum 10 wt ppm * Hg Maximum 10 wt ppb * HCl Maximum 0.01 mol ppm * HBr Maximum 0.01 mol ppm * Total Antimony (as Sb) Maximum 0.01 mol ppm * Isocyanide Maximum 0.2 mol ppm * Total Nitrogen Maximum 0.1 wt ppm * Imine Maximum 0.2 mol ppm * Nitryl Maximum 0.2 mol ppm * HCN Maximum 0.1 mol ppm * NOx Maximum 0.01 mol ppm * NH3 Maximum 1 mol ppm * Amine Maximum 0.2 mol ppm * Phosphine Maximum 0.01 mol ppm * Total Selenium (as Se) Maximum 0.01 mol ppm * Total Tellurium (as Te) Maximum 0.01 mol ppm * Total Fe Maximum 0.05 mol ppm * Total Ni Maximum 0.1 mol ppm

Note: Materials marked “*” : Poison for catalyst or bad effect on reaction.

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Table 8.3 Specification of Syn Gas fed to reaction unit (GOX)

Composition Quality (limit value) Units Purity(as H2 +CO) Minimum 98.2 mol %(dry base) CO2 Maximum 0.4 mol % CH4 +N2 Maximum 1.4 mol %

* Total chloride (as HCl) Maximum 0.01 mol ppm * Total arsenic (as H3 As) Maximum 0.01 mol ppm * Total mercury (as Hg) Maximum 0.01 mol ppm * Oxygen Maximum 1 mol ppm * Amine** Maximum 0.2 mol ppm * Total sulphur (as S) Maximum 0.1 mol ppm * Hydrogen sulfide Maximum 0.01 mol ppm * HCl Maximum 0.01 mol ppm * HBr Maximum 0.01 mol ppm * Total Antimony (as Sb) Maximum 0.01 mol ppm * Isocyanide Maximum 0.2 mol ppm * Imine Maximum 0.2 mol ppm * Nitryl Maximum 0.2 mol ppm * HCN Maximum 0.1 mol ppm * NOx Maximum 0.01 mol ppm * NH3 Maximum 1 mol ppm * Phosphine Maximum 0.01 mol ppm * Total Selenium (as Se) Maximum 0.01 mol ppm * Total Tellurium (as Te) Maximum 0.01 mol ppm * Total Fe Maximum 0.05 mol ppm * Total Ni Maximum 0.1 mol ppm

H2 O Maximum 0.34 mol % Ratio of H2/CO Maximum 1.010

Note : Materials marked “*” : Poison for catalyst or bad effect on reaction.

“**”Amine means specific amine which is used in Synthesis Gas Plant

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Table 8.4 Specification of Hydrogen Gas fed to reaction unit (GH)

Composition Quality (limit value) Units Purity(as H2 ) Minimum 99.0 mol %(dry base) Methane Balance

* CO Maximum 1 mol ppm * CO2 Maximum 5 mol ppm * Total sulphur (as S) Maximum 0.1 mol ppm * Total arsenic (as H3 As) Maximum 0.1 mol ppm * Total chloride (as HCl) Maximum 0.05 mol ppm * HCl Maximum 0.01 mol ppm * HBr Maximum 0.01 mol ppm * Total Antimony (as Sb) Maximum 0.01 mol ppm * Amine Maximum 0.2 mol ppm * Isocyanide Maximum 0.2 mol ppm * Imine Maximum 0.2 mol ppm * Nitryl Maximum 0.2 mol ppm * HCN Maximum 0.1 mol ppm * NOx Maximum 0.01 mol ppm * NH3 Maximum 1 mol ppm * Total Phosphine Maximum 0.01 mol ppm * Total Selenium (as Se) Maximum 0.01 mol ppm * Total Tellurium (as Te) Maximum 0.01 mol ppm * Total Fe Maximum 0.05 mol ppm * Total Ni Maximum 0.1 mol ppm * Total mercury (as Hg) Maximum 0.01 mol ppm * Water Maximum 5 mol ppm * Oxygen Maximum 1 mol ppm Note : Materials marked “*” : Poison for catalyst or bad effect on reaction.

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8.4 Syn Gas Unit

(1) Natural Gas @ Gujarat Refinery If Natural Gas is m a d e a v a i l a b l e f o r use as feed stock and fuel for reformer then following Natural Gas composition to be considered as provided by IOCL.

Composition of Heavy Natural gas & Light Natural gas

Heavy NG Light NG Design for Feasibility Study

Methane mol-% 78 93 94.45 2.85

Ethane (C 2 ) mol-% 7.54 2.85 Ethylene mol-% 0.46 0.15 0.15

Propane (C 3 ) mol-% 4.77 -- -

Propylene mol-% 0.23 -- -

Butanes ( C 4 ) mol-% 3 -- - - Pentanes (C 5 ) & heavier mol-% 2 --

Non-combustible gases including CO 2 and N 2

mol-% 4 4 -

CO 2 mol-% 1.95 1.95 1.95 0.55 (b)

N 2 mol-% 2 2

O 2 mol-% 0.05 0.05 Total Sulphur including H2S 6.4 ppm-v 5.1 ppm-v

0.05

6.4 ppm-v

H 2 S 5 ppm-v 4 ppm-v 5 ppm-v Impurities free from dust,

gum, sand, Oil and otherx delirious solid and / or liquid matter

free from dust, - gum, sand, Oil and otherx

delirious solid and / or liquid

matter Water content / moisture

no water or moisture shall be dehydrated and shall in no event

contain more than 112 kg of entrained

water per MMSCM gas

no water or - moisture shall be dehydrated and shall in no event

contain more than 112 kg of entrained

water per MMSCM gas

Oxygen Content 0.05 mol-% 0.05 mol-% 0.05 mol-%

Gross Heating Value kcal/SCM

kcal/Nm3

(a) Net Heating Value BTU/SCM

kcal/Nm3

(a)

11578 9323 - 10516 8409 -

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a) Calculation based on DIN 51857 (ISO 6976) b) Nitrogen composition adjusted and balanced with methane in order to reach the required synthesis gas quality.

Licenser when natural gas is the feedstock of Syngas Unit, Licenser have clarified that high nitrogen content would be 98.2 mol%. Nitrogen content shall be re-checked before the detail F/S of the project according to the gas contract.

(2) Naphtha @ Gujarat Refinery

Units Light Naphtha Heavy Naphtha Specific Gravity 0.68 - 0.7 0.69 - 0.72 API Gravity oAPI - - ASTM D86 %vol IBP oC 48 43 5 oC - - 10 oC 54 58 30 oC 69 74 50 oC 83 88 70 oC 97 105 90 oC 113 137 95 oC 119 145 FBP oC 124 156 – 165 Total sulphur wt. ppm 400 600 Mercaptan sulphur wt. ppm 350 550 Sulphur as H2S, wt. ppm 50 50 Nitrogen wt. ppm 5 5 H 2 0 wt. ppm 200 200 Heavy metals, total of Pb, As, V, Cu, Ni

wt. ppb Max 80 Max 80 Chlorine wt. ppm 6 6 Calorific Value (net)

Kcal/kg 10,534 10,510 R V P @ 38 oC Kg/cm² 0.54 – 0.7 0.43 – 0.7 Paraffin’s wt % 80 Balance Olefins wt % - 0.5 Naphthenes wt % 14 17 (max. 21) Aromatics wt % 6 8 (max. 10) MW kg/kmol 89.2 96.7 C/H ratio kg/kg 5.50 5.60

Conditions at battery limit: Pressure kg/cm2g 4.0 Temperature o C 40

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8.5. CPP Unit

(1) Petcoke @ Gujarat Refinery

Petcoke composition as provided by IOCL is mentioned as below.

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9. CATALYSTS AND CHEMICALS (for Process units)

9.1 AA/BA Plant

Major Catalysts and Chemicals for AA/BA Plant are mentioned as following.

- MCC Oxidation Catalyst - Catalytic Combustion Catalyst

Any specific data and information for all catalyst and chemical will be informed after catalyst supply agreement between MCC and IOCL.

9.2 OXO Plant

1) Catalyst (Rh Catalyst for OXO Reaction)

(a) Name O-Catalyst

(b) Chemical HRhCO(TPP)3

(c) Use Catalyst for OXO reaction

2) Triphenylphosphine (TPP)

(a) Appearance White or pale yellow flake

(b) Purity Minimum 99.8 wt%

(c) Total chlorine (as Cl) Maximum 5 wt ppm

(d) Total sulfur (as S) Maximum 5 wt ppm

(e) Total arsine (as As) Maximum 2 wt ppm

(f) Transparency of CCl4 sol Minimum 98 %

3) H-Catalyst

(a) Name H-Catalyst

(b) Main Composition Ni and Cr

(c) Use Catalyst for hydrogenation

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4) Toluene (TOL)

(a) Appearance Clear liquid free of suspended solids


(c) Specific gravity (15/4℃) 0.867 – 0.873

(d) Paraffin Maximum 0.1 wt%

(e) Total chlorine (as Cl) Maximum 5 wt ppm

(f) Total sulfur (as S) Maximum 5 wt ppm

(g) Total arsenic (as As) Maximum 0.1 wt ppm

(h) Copper corrosion test No change

(i) Sulfuric acid test (APHA) Maximum 2

(j) Reaction Neutral

(k) Color Lighter than K2 Cr2O7 soln. (0.0088g/cm3)

(l) Water solubility Not become cloudy

(m) Distillation test (within 1 deg.C) 100% which covers 110.5+0.1 deg.C

(n) Acidity No free acid

5) Iso-Propanol (IPA)



(c) Color (APHA) Maximum 10

(d) Specific gravity (20/20℃) 0.786– 0.787

(e) Water content Maximum 0.2 wt%

(f) Free acid (as acetic acid) Maximum 0.001 wt%

(g) Non volatile Maximum 0.001 wt%

(h) Water solubility Not become cloudy

(i) Total sulfur (as S) Maximum 5 wt ppm

(j) Total chlorine (as Cl) Maximum 5 wt ppm

(k) Total arsenic (as As) Maximum 0.2 wt ppm

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6) Dimethyl Lauril Amine (DLA)

Molecular formula CH3 (CH2 )11 N(CH3 )2 Specification


(b) Color(APHA) Maximum 30

(c) Total amine value 254.0-265.0 mg-KOH/g

(d) Tertiary amine Minimum 98.0 wt%

(e) Primary and secondary amine Maximum 0.3 wt%

(f) Water Maximum 0.2 wt%

(g) Alkyl(C12 ) Minimum 97.0 wt%

7) Normal Butanol (NBA):

This is used as the solvent at the initial startup only Same specification as to the Product described in 7.4

8) Iso-Butanol (IBA):

This is used as the solvent at the initial startup only Same specification as to the Product described in 7.5

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9.3 Syn Gas Unit

1) PDS Hydrogenator / Hydrogenator

(a) Catalyst Name TK-261 / Hydrogenation Catalyst

(b) Catalyst Supplier HALDOR TOPSOE

(c) Properties

• Size 2.5 mm

• Shape Asymmetric quadralobes

• Composition (typical) wt% NiO 2.3 / MoO3 9.8 / Al2O3 Balance

• Filling Density kg/l 0.5

2) Sulphur absorber

(a)

Catalyst Name HTZ-51 / Absorbent Catalyst for low sulphur concentrations


(c) Properties

• Size 4 mm

• Shape Extrudate

• Composition (typical) wt% ZnO >97%

• Max. capacity, kg S per m3 HTZ 430

• Temp. Range 200 - 400

3) Prereformer

(a) Catalyst Name RKNGR / Prereforming catalyst


(c) Properties

• Size 4.5 x 4.5 mm

• Shape Cylinder-shaped tablet

• Composition (typical) Ni, Al2O3, MgO

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4) Tubular Reformer

(a) Catalyst Name R-67-7H / Reforming catalyst


(c) Prosperities

• Size 20 x 18 mm (OD x H)

• Composition (typical) Ni , SiO2

5) Chlorine Absorbers

(a) Catalyst Name HTG-1 / Chlorine Absorbent Catalyst


(c) Prosperities

• Size 5 mm

• Shape Extruded Ring

• Composition (typical) K2CO3 / Activated Alumina as Carrier

6) Chemical for CO2 Removal unit

- Methyldiethanolamine (MDEA) Solution

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10. PRODUCT STORAGE FACILITY

Tank capacity and days for Option-d are decided based VE meeting @ MHI, Japan

PRODUCT TYPE OF STORAGE

STORAGE NO. OF DAYS

WORKING CAPACITY, M3 (1)

N-Butanol Internal Floating Roof

3 Days/Tank 1025 x 1 Tank

I-Butanol Internal Floating Roof

7 Days/Tank 232 X 2 Tanks

Acrylic Acid Cone Roof 6 Days 1583 x 1 Tank Glacial Acrylic Acid Cone Roof -NA- -NA- Butyl Acrylate Cone Roof 7 Days/Tank 3617 x 2 Tanks Propylene at Gujarat Refinery

Mounded Bullets 2.5 Days/Bullet 1770 x 2 Bullets

Propylene at Dumad Mounded Bullets 2 Days/Bullet 1410 x 1 Bullet *** Naphtha (For Syn Gas Unit)

Internal Floating Roof

3 Days/Tank 468 X 2 tanks

*** Total Propylene storage capacity including both the sites is considered as 7 days.

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11. LIST OF NEW FACILITIES FOR UTILITIES AND OFF-SITES

PACKAGES

Sl.No

UNIT NAME

DUMAD

NEW

FACILITIES

UTILITY

1

Cooling Tower YES

2

Raw Water Treatment Plant YES

3

DM Water Plant YES

4 Effluent Treatment Plant (ZLD)

YES

5

Chiller Unit & HVAC Unit YES

6

Captive Power Plant YES

7 Air Compressor & Air Dryer Unit

YES

9

Nitrogen Plant YES

OFF-SITES

1

Final Product Ware house YES

2

Raw Material Storage YES

3

Product Storage YES

4 Product Drumming / Loading Facilities

YES

5

Rail Gantry facilities NO

6

Truck Gantry facilities YES

7

Flare System YES

8

Emergency Diesel Generator YES

9

Fire Facilities YES

10

New Pipeline to be laid in existing Pipeline corridor from Gujarat Refinery to Dumad site

Yes

11 New Jackwell in Mahi River No

32/42

IOCL AA / OXO

VALUE ENGINEERING

DESIGN BASIS

12. PRODUCT EVACUATION

(i) N-Butanol (NBA) and I-Butanol (IBA) products:

Dumad site is not having railway facilities, transportation of IBA shall be done by road tankers only. Truck Gantry facilities are considered at the site. Since all the N-Butanol (NBA) produced in Oxo Unit will be consumed in BA plant, there is no shipping facility for NBA.

(ii) Butyl Acrylate (BA) product:

BA is the final product from AA/BA plant. Special product drumming (200 Kg drums) and Road gantry facilities are being considered. Dedicated product ware house is considered for filled & empty drum storages. As decided 50% of the BA product will be dispatched through drumming and rest 50% through road ISO tankers.

***Note: For detail explanation about product storage & evacuation, please refer Chapter-12.2 “Product Handling & Evacuation Study” of previous Feasibility Study Report submitted in December, 2013.

33/42

IOCL AA / OXO

VALUE ENGINEERING

DESIGN BASIS

13. TIE-IN POINTS

(i) Dumad, Gujarat:

Dumad site is a new site and no utility is available there. However, Propylene, Natural Gas, Naphtha, Pet Coke will be supplied form Gujarat refinery and respective tie-in points will be shown on the Plot Plan.

Based on Gujarat Site visit, no space is available in the railway gantry area for NBA storage tanks. Therefore, Railway gantry option may not be possible.

34/42

IOCL AA / OXO

VALUE ENGINEERING

DESIGN BASIS

14. PLANT & NON-PLANT BUILDING

Option-d Plant Building Control room √ Substation √ Warehouse & Store √ Compressor shelter √ CPP √ EDG shelter √ Maintenance workshop / building

√

Truck tanker gantry √ Railway wagon gantry X Non- Plant Building Administrative building √ Canteen √ Laboratory √ Fire station √ Security gate house √ First aid room √

35/42

IOCL AA / OXO

VALUE ENGINEERING

DESIGN BASIS

15. BASIS FOR ESTIMATION

Please see the attached Appendix-1

36/42

IOCL AA / OXO

VALUE ENGINEERING

DESIGN BASIS

16. Material Classification for OXO, AA Process

Based on the clarification made during the VE Meeting, the material selection philosophy have summarized as below. Also, it is reminded that final users of petrochemical products are very much sensitive of the impurities in their feedstock, which is a product from Oxo/AA Plant, because impurities may affect the quality of the final product such as color, odor, etc.

16.1 Oxo Unit

Alcohol is produced through aldehydes and in the Oxo process almost all the streams contains aldehydes. Aldehyde is a corrosive fluid thus almost all the equipment, piping, instruments in touch with aldehyde containing fluid are made of stainless steel. Basically Carbons Steel (CS) is limited to the following fluid but before mixing with aldehyde containing streams. All others except for CS part are of stainless steel (304 series or 316 series). Details of material construction will be specified by Licenser in the Process Design Package.

Carbon steel fluids: Propylene, heat transfer salt, hydrogen, syngas, steam, cooling water, nitrogen gas, mix gas Product Alcohol tank

16.2 AA/BA Unit Acrylic Acid is a very corrosive fluid similar to acetic acid and the material requirement shall be stainless steel (minimum 304 series). Corrosion rate is temperature dependent on and where higher temperature is foreseen such as distillation bottoms, 316 series stainless steel will be applied. In addition, heavy ends including dimers of acrylic acid and other heavy components, Hast-Alloy or other equivalent material shall be used. Butyl Acrylate (BA) has almost the same nature as Acrylic acid. Only the extent of 316 series will be smaller than AA. Basically in AA/BA Unit, carbons Steel (CS) is applied to the utility streams such as steam, cooling water, nitrogen and mixed gas. Details of material construction will be specified by Licenser in the Process Design Package.

VALUE ENGINEERING REPORT FOR ACRYLICS/OXOS PLANT INDIAN OIL CORPORATION LTD.

Chapter – 4.2 Process Description

(Option-d)


Contents

ISBL Unit Number Title

3000 PROCESS DESCRIPTION FOR SYN GAS UNIT

4000 PROCESS DESCRIPTION FOR OXO UNIT

5000 PROCESS DESCRIPTION FOR AA/BA PLANT


Page: 1 of 7

Process Description of Syn Gas Unit:

1. Introduction

MHI has delivered various syngas units for Oxo Alcohol Plants applying Haldor Topsoe's technology & are well familiar with this technology as MHI is one of the authorized & preferred Contractor for Ammonia Process Plant based on Haldor Topsoe technology and has delivered a number of plants all around the world. Haldor Topsoe (hereinafter called as Topsoe) is a well-reputed technology licenser not only for ammonia plants but hydrogen plants for which the process configuration is quite similar to oxo gas (syngas) production plant. Topsoe is a major supplier of hydrogen production technology in the world as well as in Indian Refineries including IOCL. Topsoe is also a worldwide reliable supplier of catalyst for hydrodesulphurization and steam reforming for naphtha and natural gas.

2. Salient Features of Topsoe’s Syn Gas & Hydrogen

For several decades Topsoe has been active in the field of syn. gas and hydrogen providing a variety of process options, catalysts and equipment designs. Topsoe technologies cover hydrocarbon feedstocks from natural gas to heavy residue, methanol, coal and lignite, and the main process options are tubular reforming, autothermal reforming, two-step reforming, heat exchange reforming, methanol cracking and different downstream processing, in short, the catalytic process steps used in syn. gas and hydrogen production. For non-catalytic process steps such as partial oxidation, pressure swing adsorption, and CO2-removal, Topsoe has through license agreements or similar arrangements access to all technologies of interest. A continuous R&D effort is dedicated to developing in-house catalysts and process technologies. As a result Topsoe can offer to the industry efficient and economical solutions whether clients concern upgrading of existing plants or construction of new plants, and whether small, medium large syn. gas and hydrogen capacity is required. The process conditions in a Topsoe designed syn. gas and hydrogen plant are selected in order to achieve optimum operation, taking into account local conditions, cost of raw materials and utilities. Each plant is tailor-made to fulfill the Client’s requirements for a reliable and stable operation at minimum operating costs. The optimum lay-out is chosen for each Topsoe plant, taking local conditions and client’s preferences into account.

3. Main Process Steps

Process flows through the following basic sequences: Desulphurization of hydrocarbon feedstock Steam reforming at optimum steam to carbon (s/c) ratio (2.5-3.5) Final purification of syn. gas and H2 Membrane and PSA


Page: 2 of 7

The Syngas Unit consists of the following process steps:

- Pre-desulphurization of naphtha (for naphtha feedstock only)

- Desulphurization of natural gas

- Pre-reforming of natural gas/naphtha

- Topsoe's Advanced Steam Reforming

- Heat Recovery by steam generation from flue gas and reformed gas

- CO2 Removal by UOP's Amine Guard process

- Compressors for Syngas and hydrogen boosting and CO2 recycle

- Membrane Unit for Oxo Gas Production

- PSA Unit for Hydrogen Purification

4. Block Flow Diagram

5. Details of different Process Sections

5.1 Pre-Desulphurization of Naphtha

5.1.1 Purpose

In the Pre-Desulphurization section the unsaturated hydrocarbons in the naphtha feed are hydrogenated and the organic sulphur compounds are removed from the naphtha by catalytic conversion to hydrogen sulphide which is separated from the naphtha by stripping. The naphtha predesulphurization section is included as a primary processing step to remove the bulk of the maximum 600 wt ppm sulphur. It does not


Page: 3 of 7

yield sufficiently low sulphur concentration in the feed to prevent poisoning of steam reforming catalyst, so a final desulphurization must also be performed.

5.1.2 Chemical Reaction

RSH + H2 → RH + H2S R1SSR2 + 3H2 → R1H + R2H + 2H2S R1SR2 + 2H2 → R1H + R2H + H2S (CH)4S+4H2 → C4H10 + H2S COS+H2 → CO+ H2S R is a radical of hydrocarbon. Besides the above mentioned hydrogenation of sulphur compounds, the catalyst also hydrogenates olefins to saturated hydrocarbons and organic nitrogen compounds are to some extent converted to ammonia and saturated hydrocarbons. The recommended operating temperature for the catalyst is about 3800C and at temperature below 3300C a poor hydrogenation will result and at temperature above 4000C the tendency for polymerization and coking on the catalyst is increased. Hydrogen should always be present in feed. Prolonged exposure of the catalyst to naphtha and no H2 will result in coking of the catalyst. A hydrogen flow giving a hydrogen partial pressure of 10 kg/cm2 is foreseen.

5.1.3 Process

The naphtha process feedstock is supplied at a pressure of 6 kg/cm2g to the naphtha surge drum. The naphtha is sent to the raw naphtha surge drum and pumped to approximately 32 kg/cm2g by the raw naphtha feed pump. The naphtha is mixed with off gases from the naphtha separator, and H2 recycle from the PSA unit. Prior to desulphurization, the naphtha is vaporized in the Feed/Effluent exchanger reaching a temperature of approximately 310 0C. The naphtha is fed to the PDS hydrogenator at 380 0C, after heating in the Naphtha superheater. The naphtha is cooled down to approximately 400C by passing the process gas through the Feed/Effluent exchanger, the naphtha air cooler and finally through the Naphtha Cooler. Liquid naphtha is separated in the Naphtha Separator. Liquid naphtha is heated in Stripper Feed Pre-heater and fed to the H2S stripper. Hydrogen Sulfide is removed by stripping in the H2S stripper and the sweet naphtha is cooled in stripper feed heater and sent to the Naphtha Surge Drum. Off gases from the naphtha separator and the stripper overhead separator are sent as secondary fuel to the primary reformer. Naphtha Surge Drum supplies naphtha for fuel and through the Naphtha Feed Pump, naphtha for the desulphurization section.


Page: 4 of 7

5.2 Desulphirization of natural gas

The desulphurization section has been designed with only one vessel containing zinc oxide. It has been assumed that the only sulphur compound present is H2S. This means that both hydrogen recycle and the installation of a hydrogenator are not required. Due to the low amount of sulphur in the natural gas (max. 25 ppm), the amount of catalyst is small, and only one vessel is required.

5.3 Pre-Reforming of natural gas/naphtha

In the Reforming section, hydrocarbon feed is converted into the synthesis gas consisting mainly of H2, CO and CO2 besides a minor amount of methane. The steam reforming takes place in two steps, first in Pre-Reformer and then in the tubular reformer.

5.3.1 Purpose

The main purpose of the prereformer is to reform all higher hydrocarbons completely simultaneously with methane reforming. In addition, incorporation of the prereformer has several advantages:

• Considerable energy savings are obtained because heat recovered in the convection section of the tubular reformer can be utilized for additional preheating of feed to the tubular reformer radiant section. Alternatively this heat would be used for steam production.

• Operation with lower steam to carbon ratio becomes possible hereby reducing the mass flow through the plant. Also greater flexibility to variations in the steam to carbon ratio and feedstock composition is allowed.

• Prolonging life of tubular reformer catalyst due to pre reformed catalyst will also act as guard.

The pre-reformer catalyst contains magnesia, which under certain conditions may react with steam to form magnesium hydroxide according to hydration reaction: MgO + H2O → Mg(OH)2 Hydration may mechanically destroy the catalyst cylinders. It must be ensured that catalyst is heated up to a temperature above the hydration temperature before steam is added during start-up, and that steam is cut off and purged out before the temperature has dropped too much during shut down. In the operation of the prereformer, carbon lay-down is only possible in case of very low steam/carbon ratio or in case of thermal cracking due to overheating of rich gas feed. However proper operation in order to control the steam to carbon ratio to design levels and assuring a minimum steam flow through pre`reformer will prevent carbon lay down on catalyst.


Page: 5 of 7

5.4 Steam Reforming

(a) Theoretical and Experimental Background The performance of a steam reformer depends on a very complex interaction between heat transfer and reaction kinetics. To facilitate a theoretical treatment, the heat transfer is broken down into heat transfer. -by radiation from burner blocks and furnace walls -by convection from gas to tube walls -through the tube wall -from the tube wall through the inner gas film to the catalyst bed -through the catalyst bed The reaction kinetics depends on the feed composition and properties of the nickel based steam reforming catalysts. (b) The Topsoe Reformer Design In the Topsoe reformer, the catalyst tubes are placed in a single row in a side fired furnace. Flue gas is removed through a duct above the furnace. The radiant wall burners fire backwards on heat-resistant bricks, which in turn heat the reformer tubes by radiation.

The side fired design offers some significant advantages:

- A controlled heat input along the entire length of the catalyst tubes is achieved by using multiple burners.

- The use of radiant wall burners with no forward movement of the flame eliminates the risk of flame impingement on the tubes. This is especially important for reformers operating with preheat of combustion air.

- Smooth control of the heat input from virtually zero to full capacity is possible since each burner has a rated operating range from about 25 to 125% of the normal capacity.

For the reformer tubes Topsoe materials with very high creep rupture strength in order to minimize the tube wall thickness. The materials, 25/35 Cr Ni Nb, or 25/35 Cr Ni Nb Ti have been used extensively in industrial reformers.

- Composition

- Catalyst shape and dimensions

- Free nickel surface (which depends on the degree of reduction, sulphur and other poisons, mechanical plugging, and sintering)

- Diffusion through the pore system

- Coke formation

It is necessary to study the reforming process at realistic conditions, using full-size catalyst particles loaded in an industrial reformer tube. For this reason, Topsoe is


Page: 6 of 7

operating in Houston, Texas, a complete research facility with an industrial size monotube reforming unit, permitting investigations required for establishment of the fundamental knowledge necessary for design of reformers and understanding of their operation.

(c) Process Condition

The process conditions in the steam reformer have been selected in order to give the required conversion of methane with the lowest investment cost. The steam to carbon (s/c) ratio is low in order to minimize the amount of CO2 to be removed and recycled. A low s/c ratio also decreases the size of the reformer.

A low s/c ratio, however, increases the amount of methane in the syngas. In order to compensate for this, a high outlet temperature from the reformer has been selected. The combination of low s/c ratio and high outlet temperature is only possible in a side fired reformer furnace as discussed in the enclosed article.

(d) Reforming Catalysts

The central role of the reforming catalyst is to obtain the required conversion of the hydrocarbon feed at the lowest possible tube wall temperatures, the optimum pressure drop, at the same time avoiding formation of carbon.

The pressure drop is inversely proportional to the particle size. The optimum size and pressure drop is therefore selected in each project.

The light feedstocks such as natural gas and refinery off-gases, the optimum choice is the Topsoe seven hole R-67-7H catalyst. Compared to a ring-shaped catalyst with similar dimensions, the R-67-7H catalyst has an external surface area which is about 40% higher.

Industrial experience has shown that at a given CH4 leakage, the higher external surface area of the catalyst permits operation at a tube wall temperature which is more than 20°C lower than when operating with other commercially available catalysts. As a rule of thumb, lowering the tube wall temperature by 20°C doubles the lifetime of the tubes. The 7-hole catalyst has a mechanical strength equal to, or even


Page: 7 of 7

higher, than the strength of other primary reforming catalysts available on the market today.

6. CO2 Removal Unit Typically an Amine Guard II unit, using activated MEA (approx..30 wt% MEA solution with corrosion inhibitors) for CO2 removal has been chosen. This process will undoubtedly have the low energy consumption for the process conditions selected. The CO2 is removed from the gas by absorption in an MDEA solution, which contains an activator. The activator increases mass transfer rate of CO2 from the gas phase to the liquid phase.

7. Membrane and PSA

The combination of membrane and PSA is the most simple method of separating the gas from the CO2 removal unit into the required syngas and hydrogen products. The membrane unit has no moving parts and requires very little attention and maintenance. Due to the strict requirement for the H2 product purity it has been necessary to include a PSA unit. Membrane Unit In the membrane unit excess amount of hydrogen is removed by diffusion through a semi permeable membrane so that desired H2/CO molar ratio of 1.01 is obtained in OXO gas product. PSA Unit The PSA unit consists of a number of beds operating in cycles. Impurities are selectively adsorbed on an adsorbent at a high pressure hereby producing high purity Hydrogen. By reducing the pressure, the impurities are desorbed and there by adsorbent is regenerated. Every adsorber operates on a repeated cycle basis consisting of adsorption and regeneration phases (swing) without changes in temperature, except for those caused by the heat of adsorption and desorption.


Chapter – 4.3 Block Flow Diagram

(Option-d)

VALUE ENGINEERING REPORT FOR ACRYLICS/OXOS PLANTY INDIAN OIL CORPORATION LTD.

Chapter – 4.6 Utility Consumption List

(Option-d)

REV. 0 1

DATE 31-07-2014 26-03-2015

Prepared By ABU ABU

Checked By SBY SBY

Approved By VPS VPS

Electricity

BHP HP Steam MP Steam LP Steam LLP Steam

MP SteamCondensate

LP SteamCondensate HP BFW MP BFW LP BFW

CoolingWater

Refrigerated Water(RW5)

Refrigerated Water(RW15)

DemineralizedWater

IndustrialWater Potable Water Fire Water

Pet CokeFor CPP Naphtha Fuel Oil

NaturalGas

InstrumentAir Plant Air

High PressureNitrogen (HN)

Low PressureNitrogen (N)

Low Low Pressure Nitrogen (LN)

Kg/h Kg/h Kg/h Nm3/h

PRESS30 kg/cm2g

PRESS15 kg/cm2g

PRESS5 kg/cm2g

PRESS2 kg/cm2g

PRESS1.5 kgc/m2g

PRESS1.5 kgc/m2g

PRESS PRESS25 kg/cm2g

PRESS PRESS4.5 kg/cm2g

PRESS6 kg/cm2g

PRESS6 kg/cm2g

PRESS7 kg/cm2g

PRESS3.5 kg/cm2g

PRESS4.5 kg/cm2g

PRESS7 kg/cm2g

PRESS PRESS PRESS PRESS PRESS7 kg/cm2g

PRESS7 kg/cm2g

PRESS30 kg/cm2g

PRESS5 kg/cm2g

PRESS1.5 kg/cm2g

TEMP.236 °C

TEMP.201 °C

TEMP.159 °C

TEMP.132 °C

TEMP.130 °C

TEMP.130 °C

TEMP. TEMP. TEMP. TEMP.35 °C

TEMP.5 ° C

TEMP.15 ° C

TEMP.40 °C

TEMP. Amb. TEMP. Amb. TEMP. Amb. TEMP. TEMP. TEMP. TEMP. TEMP. Amb TEMP. Amb TEMP. Amb TEMP. Amb TEMP. Amb

3000 SYN GAS UNIT 1909 -2.1 8.8 -8.9 452 6.6 4433 400 0

4000 OXO PLANT 970 12 31 -12 -31 3300 43 -390 150 100

5000 AA / BA PLANT 4700 90 -55 7700 709 410 30 0 750 330 700

7000 UTILITY 7200 <1.5> <-1.2> 3500 43.4 323 14620 0 200

Total Consumption 14779 90 9.9 39.8 -12 -94.9 14952 752 410 50 353 {*} {*} 14620 4433 -390 0 1500 330 800

NOTES : A positive value indicates quantity consumed. A negative value (-) indicates quantity produced. < > indicates process intermittent service. { * } indicates other intermittent service.

Page -3

Ton/h Ton/h Ton/h Ton/h Nm3/h Nm3/h

UTILITY CONSUMPTION LISTCONFIDENTIAL

UTILITY REQUIREMENTS @ 100% Load IOCL AA/OXO VALUE ENGNEERINGOption- dCUSTOMER: IOCL, INDIA

AreaNumber Unit

Steam Steam Condensate BFW Water Fuel AIR Nitrogen

kW


Page: 1 of 1

Chapter – 5 Utility & Off-Sites Facilities

(Option-d)

Type of PlantRaw Water Treatment

Demi Water Unit

Effluent Treatment Nitrogen Product

Druming

Truck Loading Gantry

Flare Stack

Emergency Generator

Fire Fighting Facility

Value Engineering

Coo

ling

Wat

er P

umps

No.

x D

esig

n C

apac

ity, m

3/h

Coo

ling

Tow

erN

o. o

f Cel

lsTo

tal C

ircl.

Rat

e, T

/h

Cap

acity

, T/h

Cap

acity

, T/h

Type

: ZLD

Cap

acity

, m3/

h

Dut

y: k

W, F

low

T/h

No.

Uni

t x C

hille

r Cap

acity

(C

hille

r Ton

)

Pow

er G

ener

atio

n, M

W

Boile

r Ste

am G

ener

atio

n t/h

No.

of C

ompr

esso

r x D

esig

n C

apac

ity (N

m3/

hr)

No.

of A

ir D

ryer

x D

esig

n C

apac

ity (N

m3/

hr)

N2 G

ener

atio

n C

apac

ity

(Nm

3/hr

)

Prod

uct :

No.

of D

rum

s Lo

adin

g M

achi

nes

No.

of B

ays

Gas

Pro

cess

ing

Cap

acity

(N

m3/

hr)

No.

x C

apac

ity, M

W

Fire

Wat

er R

equi

rem

ent

Option-d Design (3+1)5,500

(4+1)16,800 530 65 155 1000 (4+1) x

320 17 200 1 x 2,000

1 x 1,500 900 3 3 81000 1 x 1.5

Same as FS

Report

DESIGN CAPACITIES OF MAJOR OSBL FACILITIES (Option-d)

Cooling Water Facility

UTILITIES OFFSITES

CPPChilled Water IA/PA System


Page: 1 of 4

Chapter – 6 Project Execution Philosophy

(Option-d)


Page: 2 of 4

6. Project Execution Philosophy 6.1 Introduction

This Value Engineering report is prepared considering LSTK mode as per the discussion during Value Engineering meeting in MHI, Japan. The project shall be executed in two phases: (i) Phase-1 and (ii) Phase-2. Phase-1: This phase will start with the activity of selection of Licensors, PMC and Consultants for REIA/RA. IOCL Board’s approval for the project shall be obtained during this phase only. This phase will be completed with the award to LSTK contractor. Phase-2: This phase will start with the award of LSTK contractor and will continue till the successful Performance Test Run. Separate Project Schedules are prepared for these two phases which explain the different activities in detail. For Project Schedule please refer Chapter-7 of this Value Engineering Report.


Page: 3 of 4

6.2 LSTK mode execution Block Diagram Following block diagram represents the typical LSTK mode of project execution.

IOCL-JV

Technology Supplier/ Licensor Project Management Consultant

Basic Engineering Package (BEP)

Supply -Proprietary items & Catalysts

Project Management

Training At Design Office & At similar operating plant

Review of some detail engineering documents

Preparation of LSTK Package

Selection Of LSTK Contractor

Ordering of Long Lead Item, if required

LSTK Contractor


Page: 4 of 4

6.3 Project Implementation plan

6.3.1 Phase-1 Following list provides sequence of activities for execution in Phase-1:

1. Selection & award to Licensors for BEP 2. Selection & award to PMC 3. Selection & award to REIA/RA Consultants 4. Basic Engineering, Process Design package by Licensors 5. Start of DFR & FEED by PMC 6. Completion of DFR & FEED by PMC 7. Environmental & other clearances and permits for project approval 8. IOCL board Approval for the Project 9. Selection and award to Site Development Contractor 10. Preparation of LSTK Tender by PMC 11. Start of ordering of Long Lead items (LLI) by PMC, if required 12. Submission of bids by LSTK contractors 13. Sorting out Techno-Commercial Queries / Clarifications from LSTK bidders 14. Price bid opening and negotiation with LSTK bidders 15. Board approval for award of LSTK contract

6.3.2 Phase-2

Following list provides sequence of major activities for execution in Phase-2:

1. Residual Basic engineering by PMC 2. Detail engineering by LSTK Contractor 3. Ordering of Utility & Off-sites packages by LSTK Contractor 4. Placing Procurement Order by LSTK Contractor except for Long Lead Items under

Phase-1 5. Construction & Erection by LSTK Contractor 6. Mechanical Completion 7. Preparation for Pre-Commissioning 8. Pre-Commissioning 9. Start-up / Commissioning 10. Performance test run


Page: 1 of 3

Chapter – 7

Project Implementation Schedule

(Option-d)


Page: 2 of 3

Phase 1-Schedule

IOCL AA/OXO-Phase-1 Project Schedule

TimeMonths 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Sl. No.

Activities

1.0 Licensor Selection 2

2.0 Technology Package Development

6

3.0 PMC-I line up Line up for feasibility study and +/-20% cost estimate

2

4.0 Cost estimate (+/-20% cost accuracy based on TDP)

3

5.0 Stage-2 approval from Chairman

1

6.0 FEED & DFR preparation 5

7.0 Investment Approval / Board Approval

1


Phase-2 (Project Implementation Schedule)

Page: 3 of 3

# Activity ID Activity Name Original Duration

1 IOCL_AA/OXO-LIOCL_AA/OXO-LSTK App IOCL_AA/OXO_Project Implemen 1368d

2 IOCL_AA/OXO-IOCL_AA/OXO-LSTK App.M Milestones 1308d

3 M1030 Board Approval 0d

4 M1040 Start of Ordering for Long Lead Items 0d

5 M1050 Board Approval of LSTK Contractor 0d

6 M1060 Construction work start 0d

7 M1070 Start of Pre Commissioning/Commissioning

0d

8 M1080 Performance Test Completion 0d

9 IOCL_AA/OXO-IOCL_AA/OXO-LSTK App.P Project Implementation 1368d

10 A1050 Board Approval 60d

11 A1060 LSTK Tender Preparation 60d

12 A1065 Procurement of Long Lead Equiments by PMC

600d

13 A1070 Site Preparation work 180d

14 A1075 LSTK Offers received 90d

15 A1080 Technical & Commercial Queries 60d

16 A1090 Price bid Opening & Negotiation 60d

17 A1100 Board approval for LSTK Contractor 60d

18 A1110 Residual Basic Engineering 180d

19 A1120 Detail Engineering 390d

20 A1130 Utilities & Offsites Packages 720d

21 A1140 Procurement Other Equipments 600d

22 A1150 Construction 720d

23 A1160 Mechanical Completion 0d

24 A1170 Preparation for Pre-commissioning 60d

25 A1180 Pre Commissioning / Commissioning 120d

26 A1190 Performance & Test Run 30d

-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48Month

IOCL_AA/OXO-LSTK App

IOCL_AA/OXO-LSTK App.M

Board Approval

Start of Ordering for Long Lead Items

Board Approval of LSTK Contractor

Construction work start

Start of Pre Commissioning/Commissioning

Performance Test Completio

IOCL_AA/OXO-LSTK App.P

Board Approval

LSTK Tender Preparation

Procurement of Long Lead Equiments by PMC

Site Preparation work

LSTK Offers received

Technical & Commercial Queries

Price bid Opening & Negotiation

Board approval for LSTK Contractor

Residual Basic Engineering

Detail Engineering

Utilities & Offsites Packages

Procurement Other Equipments

Construction

Mechanical Completion

Preparation for Pre-commissioning

Pre Commissioning / Commission

Performance & Test Run

IOCL_AA/OXO_Project Implementation Schedule-LSTK Mode_30-Mar-15_ Approved IOCL AA_OXO_L1 LEVEL SCHEDULE-LSTK 31-3-15 10:23

Actual Level of EffortPrimary Baseline

Actual WorkRemaining Work

Critical Remaining WorkMilestone

Page 1 of 1 TASK filter: (Untitled Filter).© Oracle Corporation

# Activity ID Activity Name Original Duration

1 IOCL_AA/OXO-CIOCL_AA/OXO-Con.App IOCL_AA/OXO_Project Implementa 1431d

2 IOCL_AA/OXO-CIOCL_AA/OXO-Con.App.M Milestones 1371d

3 M1030 Board Approval 0d

4 M1040 Start of Ordering for Long Lead Items 0d

5 M1050 Approval of Construction Contractor 0d

6 M1060 Construction work start 0d

7 M1070 Start of Pre Commissioning/Commissioning

0d

8 M1080 Performance Test Completion 0d

9 IOCL_AA/OXO-CIOCL_AA/OXO-Con.App.P Project Implementation 1431d

10 A1050 Board Approval 60d

11 A1055 Selection of Engineering Consultant 60d

12 A1058 Residual Basic Engineering 180d

13 A1059 Detail Engineering 390d

14 A1060 Preparation of Construction Package(Civil,Mechanical,E&I)

60d

15 A1070 Site Preparation work 180d

16 A1075 Construction Contractor Offers received

60d

17 A1080 Technical & Commercial Queries 30d

18 A1100 Approval for Construction Contractor 60d

19 A1120 Procurement of Long Lead Equiments by Engineering Consultant

600d

20 A1130 Utilities & Offsites Packages 720d

21 A1140 Procurement Other Equipments 600d

22 A1150 Construction 795d

23 A1160 Mechanical Completion 0d

24 A1170 Preparation for Pre-commissioning 60d

25 A1180 Pre Commissioning / Commissioning 120d

26 A1190 Performance & Test Run 30d

-2 -1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50Month

IOCL_AA/OXO-Con.App

IOCL_AA/OXO-Con.App.M

Board Approval

Start of Ordering for Long Lead Items

Approval of Construction Contractor

Construction work start

Start of Pre Commissioning/Commissioning

Performance Test Complet

IOCL_AA/OXO-Con.App.P

Board Approval

Selection of Engineering Consultant

Residual Basic Engineering

Detail Engineering

Preparation of Construction Package(Civil,Mechanical,E&I)

Site Preparation work

Construction Contractor Offers received

Technical & Commercial Queries

Approval for Construction Contractor

Procurement of Long Lead Equiments by Engineering Consultant

Utilities & Offsites Packages

Procurement Other Equipments

Construction

Mechanical Completion

Preparation for Pre-commissioning

Pre Commissioning / Commissio

Performance & Test Run

IOCL_AA/OXO_Project Implementation Schedule-Con Mode_30-Mar-15_Approved Conventional Mode 31-3-15 10:32

Actual Level of EffortPrimary Baseline

Actual WorkRemaining Work

Critical Remaining WorkMilestone

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