FINAL REPORT
FOR
FEASIBILITY STUDY WITH ±30% COST ESTIMATES FOR
CAPACITY EXPANSION OF PANIPAT REFINERY
FROM 15.0 MMTPA TO 25.0 MMTPA
INDIAN OIL CORPORATION LIMITED
REPORT NO: A328‐RP-79-41‐0002
VOLUME 1 OF 1
NOVEMBER 2017
This report is prepared for M/s IOCL and it is for use by M/s
IOCL or their assigned representatives/organizations only.
The matter contained in the report is confidential.
FINAL REPORT
FOR
FEASIBILITY STUDY WITH ±30% COST ESTIMATES
FOR CAPACITY EXPANSION OF PANIPAT REFINERY
FROM 15.0 MMTPA TO 25.0 MMTPA
CLIENT
INDIAN OIL CORPORATION LIMITED
PREPARED BY
ENGINEERS INDIA LIMITED
NEW DELHI
EIL JOB No.: A328
REPORT No. A328-RP-79-41-0002
VOLUME 1 OF 1
NOVEMBER 2017
Copyright
This document is copyright protected by EIL and is produced for the client M/s IOCL.
Neither this document nor any extract from it may be produced, stored or transmitted in
any form for any purpose by any party without prior written permission from EIL.
Request for additional copies or permission to reproduce any part of the document for
any commercial purpose should be addressed as shown below:
Head of Department
Process-2 Department
Engineers India Limited
R&D Complex
Sector-16, Gurgaon
Haryana-122001
India
Phone : +91-124-3803701
EIL reserves the right to initiate appropriate legal action against any unauthorized use of
its Intellectual Property by any entity.
Table of Contents
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Page 1 of 1
TABLE OF CONTENTS
CHAPTER
CONTENTS
PAGE
1.
EXECUTIVE SUMMARY
1 of Ch 1
2.
INTRODUCTION
1 of Ch 2
3.
SCOPE OF WORK
1 of Ch 3
4.
BASIS OF STUDY
1 of Ch 4
5.
MARKET STUDY
1 of Ch 5
6.
PROJECT LOCATION
1 of Ch 6
7.1
PROJECT DESCRIPTION
1 of Ch 7.1
7.2
REFINERY CONFIGURATION STUDY
1 of Ch 7.2
7.3
PROCESS DESCRIPTION
1 of Ch 7.3
7.4
MATERIAL BALANCE
1 of Ch 7.4
7.5
UTILITIES DESCRIPTION
1 of Ch 7.5
7.6
LOGISTICS
1 of Ch 7.6
7.7
OFFSITES DESCRIPTION
1 of Ch 7.7
7.8
SULFUR BALANCE
1 of Ch 7.8
7.9
HYDROGEN BALANCE
1 of Ch 7.9
8.
ENVIRONMENTAL CONSIDERATIONS
1 of Ch 8
9.
PROJECT IMPLEMENTATION AND SCHEDULE
1 of Ch 9
10.
PROJECT COST ESTIMATE
1 of Ch 10
11.
FINANCIAL ANALYSIS
1 of Ch 11
12.
HEALTH SAFETY AND ENVIRONMENT
1 of Ch 12
13.
RECOMMENDATIONS
1 of Ch 13
ANNEXURES
No. of pages
1
BLOCK FLOW DIAGRAM
01
2
INDICATIVE PLOT PLAN
02
3
SCHEMATIC FLOW DIAGRAM
18
4
PROJECT SCHEDULE
01
5
COSTING SHEETS
05
6
CRUDE ASSAYS
16
7
FEED AND PRODUCT PROPERTIES
11
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 1 of 39
CHAPTER 1
EXECUTIVE SUMMARY
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 2 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
1.0 EXECUTIVE SUMMARY
1.1 Introduction
Panipat refinery, a unit of Indian Oil Corporation Limited (IOCL) operates a 15.0 Million
Metric Tons Per Annum (MMTPA) oil refinery at Panipat in Haryana. The refinery was
commissioned in 1997-98 and started off with a crude oil processing capacity of 6.0
MMTPA (PR- Panipat Refinery). The refinery capacity was raised to 12.0 MMTPA with
the addition of another crude unit and a full conversion hydrocracker as the secondary
processing unit and Delayed Coker unit for bottom processing (PREP- Panipat Refinery
Expansion Project). Through progressive revamps and addition of process units the
refining capacity has been brought to the present operating capacity of 15.0 MMTPA
(PRAEP- Panipat Refinery Additional Expansion Project). IOCL Panipat is also
integrated with Naphtha Cracker and Aromatic Complex.
The existing refinery consists of the following unitsTable 1.1.1
PANIPAT REFINERY (PR) UNITS
S.NO.
UNIT NAME
UNIT NO.
CAPACITY
LICENSOR
1.
2.
CDU, VDU
NSU-1 REVAMP
3
1.312 MMTPA
TECHNIP KTIL
3.
OHCU
5
1.9 MMTPA
UOP, IOCL
4.
HGU
6
38 KTPA
HALDAR TOPSOE
5.
RFCCU
7
0.85 MMTPA
SWEC,IOCL,EIL
6.
PSU
33
0.255 MMTPA
EIL
7.
CRU
8
IFP - AXENS
8.
DHDS
52
0.64 MMTPA
0.55 MMTPA
9.
VBU
9
0.4 MMTPA
EIL
10.
BBU
ATF MEROX (Converted
from Gasoline Merox)
LPG MEROX
10
0.5 MMTPA
EIL
12
30 m3/hr
UOP, IOCL, EIL
13
50 m3/hr
UOP, IOCL, EIL
ATF-KERO MEROX
SRU/SSRU ( Common
Incinerator)
ARU
15
180 m3/hr
22/44
115 TPD
21
400 m3/hr
UOP
DELTA HUDSON
- EIL
EIL
71.8 m3/hr
EIL
16.4 m3/hr
EIL
11.
12.
13.
14.
15.
16.
03, 04, 19
SWS-I (REFINERY)
17
SWS-II
17.
18
(HYDROPROCESSING)
PANIPAT REFINERY EXPANSION (PRE) UNITS
Template No. 5-0000-0001-T2 Rev. 1
7.5 MMTPA
(Based on BS VI - FR)
EIL,IOCL
IFP - AXENS
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 3 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
S No
UNIT NAME
UNIT NO.
CAPACITY
1.
CDU, VDU
2.
NSU-2
3.
73, 74
7.5 MMTPA
EIL
59
0.72 MMTPA
TECHNIP KTIL
HGU
76, 77
2 X 70 KTPA
HALDER TOPSOE
4.
HCU
75
1.9 MMTPA
UOP
5.
DCU
78
3.0 MMTPA
ABB LUMMUS
6.
7.
COKER LPG MEROX
DHDT
79
0.1 MMTPA
UOP
72
3.5 MMTPA
AXENS
8.
SRU-I
55
225 TPD
BLACK & VEATCH
9.
SRU-II
56
TGU
225 TPD
EQ.450 TPD
SULPHUR
BLACK & VEATCH
10.
410 m3/HR
BLACK & VEATCH
57
11.
ARU
51
12.
SWS-I (REFINERY)
53
13.
SWS-II (HYDROPROCESSING)
3
170 m /HR
54
40 m /HR
PARA XYLENE AND PURIFIED TEREPHTHALIC ACID (PX and PTA) UNITS
S.NO.
3
UNIT NAME
1.
NHT, CCR
2.
SHELL SULFOLANE
3.
PAREX
4.
UNIT NO.
201,
202, 203
204
CAPACITY
MMTPA
LICENSOR
BLACK & VEATCH
EIL
EIL
LICENSOR
0.628
UOP
0.115
UOP
205
2.494
UOP
XFU
206
0.693
UOP
5.
ISOMAR
207
2.203
UOP
6.
TATORAY
208
0.624
UOP
7.
BTF
209
0.615
UOP
8.
PTA
221
DUPONT
9.
ERU
-
0.7
0.227 MMTPA
(Feed)
Thyssen Krupp
MS QUALITY UPGRADATION (MSQ) UNITS
S.NO.
1.
UNIT NAME
NHT /PENEX
UNIT NO.
301
2.
CAPACITY
410 / 400
TMTPA
470 TMTPA
RSU
302
FCC GDU
C9 stream PNCP shall be routed
3.
303
445 TMTPA
to second stage HDS of Prime G
unit. (100 KTPA).
PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT (PRAEP) UNITS
S.NO.
UNIT NAME
UNIT NO.
CAPACITY
LICENSOR
UOP
IFP - AXENS
AXENS
LICENSOR
1.
SWS
20
40 m3/HR
EIL
2.
SRU-III
25
225 TPD
BLACK & VEATCH
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
3.
TGU
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 4 of 39
26
EQ.450 TPD
SULPHUR
BLACK & VEATCH
UNIT NO.
CAPACITY
LICENSOR
BS-VI UNITS
S.NO.
UNIT NAME
1.
DHDT
-
2.2 MMTPA
UOP
2.
HGU
-
44 KTPA
-
3.
SRU
-
225 TPD
Prosernet
4.
TAME
-
36 KTPA
-
5.
ARU
-
189 m3/hr
EIL
6.
SWS (Hydroprocessing)
-
7.
Octamax
-
3
56.7 m /hr
Not to be
considered in base
case
EIL
IOCL R&D
M/S IOCL is considering to increase the processing capacity of the existing refinery from 15
MMTPA to 25 MMTPA. IOCL has entrusted M/S EIL to carry out a configuration study and
preparation of feasibility report with a cost estimate of +30% for capacity expansion of
Panipat Refinery Expansion from 15 MMTPA to 25 MMTPA and screening
of various
configuration options for the proposed capacity enhancement based on preliminary
economics (GRM and Simple payback period). Detailed analysis of the two shortlisted
cases is done and recommended case is selected.
1.2 Project Objectives
The objectives of the study are to carry out feasibility study for:
 Refinery capacity expansion from 15 MMTPA to 25 MMTPA with fuels conforming to
BS VI specification by installation of new CDU/VDU of 10.0 MMTPA capacity.
 Downstream process facilities for meeting product quality specifications and other
requirements and to meet the environmental standards.
 Zero liquid discharge from new facilities to be considered.
 Zero production of Fuel Oil.
1.3 Basis of Study
With the objective of meeting the guidelines established in Auto Fuel Policy 2025 wherein it
would be required to manufacture 100% BS-VI fuels, a study was carried out by M/S EIL in
March,2016 (for existing refinery – 15.0 MMTPA) to analyze the potential for conforming to
the mandate as described above by 2020 as envisaged by Govt. of India.
In base case of Panipat Refinery, 100% BS-VI grade fuel production has been considered
and present operating scenario of Panipat Refinery has been considered.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 5 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
On-stream Hours: The on stream hours have been considered as 8000 hours/ annum.
1.3.1 Crude Mix
Base, design and check cases crude mix originally identified for the study is tabulated
below:
Table 1.3.1.1- Crude Mix
Original Expansion Case [MMTPA]
Crudes
Base Case
MMTPA
Design
case
Check
Case-1
Check
case-2
Bonny Lt.
1.0
0
2.5
0
Basrah Hy.
4.0
8.1
7.1
0
Kuwait
3.25
12
14.2
13.5
Maya
0.75
0
0
5.7
Saturno
0
3.7
0
4.6
Mangla
1.0
1.2
1.2
1.2
Iran mix
1.0
0
0
0
Arab mix
1.25
0
0
0
Forcados
0.5
0
0
0
Escravos
0.5
0
0
0
Quaiboe
0.75
0
0
0
Zaffiro
0.5
0
0
0
Bombay Hi
0.5
0
0
0
The graphical representation of crude mix is as follows:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 6 of 39
Fig. 1.3.1.1
Fig. 1.3.1.2
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 7 of 39
In the base case of present study, a blend of 15.0 MMTPA crude is made and 7.5 MMTPA
of this blend is routed to CDU-I and 7.5 MMTPA of this blend is routed to CDU-II. Similarly
for expansion cases, a blend of 25.0 MMTPA crude is made and 7.5 MMTPA of this blend is
routed to CDU-I, 7.5 MMTPA of this blend is routed to CDU-II, and balance 10.0 MMTPA of
this blend is routed to new CDU.
A comparison of the key crude properties of base case and original design case crude mix
is tabulated below.
Table-1.3.1.2
CRUDES
BASE CASE
ORIGINAL
EXPANSION
DESIGN
CASE
YIELD
DIFFERENCE
BETWEEN BASE
CASE AND
ORIGINAL
EXPANSION CASE
Specific gravity
0.873
0.885
API
30.6
28.4
Sulfur (wt%)
1.82
2.53
CCR (wt%)
5
7.1
1.07
0.8
-0.27
5.19
4.79
-0.4
10.92
9.96
-0.96
11.91
10.41
-1.49
23.96
22.18
-1.78
26.41
24.84
-1.57
Yields (wt%)
C5LIGHT NAPHTHA
(C5-90°C)
HEAVY NAPHTHA
(90°C – 165°C)
KERO
(165°C -240°C)
DIESEL
(240°C –380°C)
VGO
(380°C –565°C)
Following are the observations on the original design crude mix:



Original Design case crude mix is heavier than base case crude mix.
Original Design case crude mix is high sulfur than base case crude mix.
Average price of original design case crude mix is Rs 27132/MT and that for base
case crude mix is Rs 28524/MT.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 8 of 39
1.3.2 Feed and Product Prices
Feed and product prices were taken considering 3 years average price for the period of
April, 2014 –January, 2017. However, subsequently prices were revised for the period of
April, 2014-March, 2017.
Table 1.3.2.1- Crude and other feed streams Price
3 YEARS AVERAGE
STREAMS
(RS/MT)
(APRIL,2014-MARCH,2017)
Mangla
Bonny Light
Basrah Heavy
Basrah Light
Kuwait
Maya
Saturno (1)
Arab Mix( 80: 20)
Arab Mix( 50: 50)
Escravos
Forcados
Iran MIX (75:25)
Quaiboe
Zafiro
Bombay Hi
C4 LPG
26,094
32,154
25,134
27,388
28,218
23,155
28,322
28,866
28,102
32,128
31,808
29,147
33,062
30,401
31,218
35446
C7 to C8 streams from PNCP
43783
C-9 Streams from PNCP
(if routed to HSD)
C-9 Streams from PNCP
(if routed to MS)
C-5 Streams from PNCP
37808
43783
43783
Table 1.3.2.2- Product Price
3 YEARS AVERAGE
STREAMS
(RS/MT)
(APRIL,2014-MARCH,2017)
Fuel gas
LPG
Ethylene
Propylene (Mathura)
MS BS VI Regular
Template No. 5-0000-0001-T2 Rev. 1
22959
35446
42,375
46608
43783
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 9 of 39
3 YEARS AVERAGE
STREAMS
(RS/MT)
(APRIL,2014-MARCH,2017)
MS BS VI Premium
SKO
ATF
HSD BS VI
HSFO
Bitumen VG30
Sulphur
Coke
PNCP Naphtha (EPP)
PTA
Group II - H-70
Group II - H-150
Group II - H-500
Group III - 3 cst
Group III - 4 cst
Group III - 6 cst
Group III - 8 cst
LAB
MEG
PET
Benzene
45507
39378
38712
37808
23946
25986
7418
5115
31369
42145
39435
43943
48771
41435
43877
46319
50771
41430
47400
63231
51638
The utility import prices have been considered as follows:
Table 1.3.2.3- Utility Price
PRODUCTS
Power
UNIT
Rs/KWH
PRICE
8.45
Raw water
Rs/m3
13.49
RLNG
Rs/MT
31017
1.3.3 Major Product specifications
Specifications for BS-VI MS and Diesel have been considered as tabulated below:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 10 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Table 1.3.3.1- BS-VI MS Specification
BS-VI MS Regular
BS -VI
S. NO.
PARAMETERS
UNIT
PANIPAT
SPEC
1
Density @ 15 oC
2
Distillation
Kg/m3
720 - 775
720 - 773.7
E-70
% Vol
E-100
% Vol
10-55(summer)
10-58(other month)
40-70
E-150
% Vol
75 min
75
FBP
o C max
210
200
Residue
% Vol. Max
2
2
3
Sulphur, Total
mg/kg max
10
8
4
RON
Min.
91
91.5
5
MON
Min.
81
81.4
6
RVP @ 38 oC
Kpa
67
60
Summer (May to Jul)
Max
1050
750
Others
Max
1100
950
8
Benzene
% Vol-max
1
1
9
Aromatics
% Vol-max
35
35
10
Olefin
% Vol-max
21
21
11
Existent Gum
Gum(Solvent
washed)
g/m3-max
mg/100 ml
max
MinutesMin
g/l-max
-
-
4
5
360
360
0.005
0.005
%wt-max
3.7
2.7
11 - 45
40 - 70
VLI (10RVP+7E70)
7
12
13
Oxidation Stability
14
Lead as Pb
Oxygen content
,max
15
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 11 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Table 1.3.3.2- BS-VI MS Premium Specification
BS-VI MS Premium
BS -VI
S.NO.
PARAMETERS
UNIT
PANIPAT
SPEC
1
Density @ 15 oC
Kg/m3
720-775
720 -773.7
Distillation
10-55(summer),
E-70
% Vol
10-58(other
months)
11-45
E-100
% Vol
40 - 70
40-70
E-150
% Vol
75 min
75
C max
210
200
Residue
% Vol.
Max
2
2
3
Sulphur, Total
mg/kg
max
10
8
4
RON
Min.
95
95.5
5
MON
Min.
85
81.4
6
RVP @ 38 oC
kpa
67
60
7
VLI (10RVP+7E70)
Summer (May to Jul)
Max
1050
750
Others
Max
1100
950
8
Benzene
% Volmax
1
1
9
Aromatics
% Volmax
35
35
10
Olefin
% Volmax
18
18
2
FBP
Template No. 5-0000-0001-T2 Rev. 1
o
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 12 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
BS-VI MS Premium
BS -VI
S.NO.
PARAMETERS
UNIT
PANIPAT
SPEC
Existent Gum
g/m3-max
Gum(Solvent washed)
mg/100 ml
max
4
5
13
Oxidation Stability
MinutesMin
360
360
14
Lead as Pb
g/l-max
0.005
0.005
15
Oxygen
%wt-max
4.5
2.7
11
12
Table 1.3.3.3- BS-VI Diesel Specification
BS-VI Diesel
S No
1.
Parameters
Density at 15 oC
2.
Distillation T-95
3.
Sulfur, Total
4.
Cetane Number, min
5.
Cetane Index, min
6.
Unit
BS VI Spec
Kg/m3
845
o
C max
Mg/Kg,
max
-
360
360
10
8
51
51.4
-
46
46
C
35
42
Cst
2.0 - 4.5
2.15 - 4.5
o
Flash Point
o
Panipat
Spec
821-845
7.
Kinematic Viscosity at 40 C
8.
PAH, max
Wt %
8
11
9.
Total Contaminants, max
Mg/kg
24
24
Oxidation stability, max
Carbon Residue
(Ramsbottom) on 10 %
residue, max
Water Content, max
Lubricity Corrected WSD,
max
Ash, max
3
25
21 / 18
Wt %
0.3 (without
additive)
0.3
Mg/kg
200
200
microns
460
420
Wt %
0.01
0.01
10.
11.
12.
13.
14.
Template No. 5-0000-0001-T2 Rev. 1
gm/m
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 13 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
1.3.4 Production limits
Production limits for various grades of products as considered for this study have been
tabulated as per tables below:
Product
Table 1.3.4.1- Production Limits
Base case for expansion
study (BS – VI Case)
(000 TPA)
Expansion case - to be
provided by IOCL (Min-Max)
227
As Produced
0
As produced
RFCC Propylene
120
As Produced
Liquefied Petroleum Gas
649
As produced
Benzene
24.6
Same as Base Case
PTA
700
Off gas (FCC + DCU)
Fuel Gas
Naphtha for PNC feed
2910 (Phase-I)
Presently 60% sourcing
from Panipat and Balance
from other refineries.
Same as Base Case
Min: Same as Base Case.
Excess Naph produced in
expansion case to be routed to
PNCP by reducing Naph
Import.
Maximize
Regular Gasoline (BS VI)
1435.2
Premium Gasoline(BS VI)
229.2
As produced
0
Same as Base Case
Aviation Turbine Fuel
1125
2000
Diesel (BS-VI)
7750
Maximize
Bitumen
360
Min. Same as Base Case
High Sulfur Fuel Oil
225
Nil
Pet Coke
874
As produced
Sulphur
652
As produced
LOBS
0
As produced
LAB
0
As produced
Pitch
0
As produced
Sulfuric Acid
0
As produced
Kerosene
Table 1.3.4.2- Feed streams from PNCP and Mathura
(000
Range
Return Stream
TPA)
(*)
C4H (ex PNC)
C7-C8 (ex PNC)
C9 (ex PNC)
PFO (ex PNC)
Template No. 5-0000-0001-T2 Rev. 1
Destination
200
0-200
LPG
228
228-282
MS Pool
100
54-100
MS Pool / DHDT
112
78-112
FO
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 14 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
C5 stream (ex PNC)
170
120 170
PX feed Naphtha (ex Mathura
R efinery)
150
147-153
MS Pool (after treating
in NHDT for 'S' removal
& in Penex for RON
boosting)
PX / PTA
Note: (*) Maximum value to be considered for expansion case, except for C7-C8 stream, for
which 228 KTPA is to be considered for expansion case
1.3.5 Other considerations of the study
Other considerations for the study are as follows.
 Base case to be prepared including TAME unit, Revamp of Prime-g and PX-PTA unit.
 Plot plan of BS VI project shall be considered for this study.
 Power import shall be considered for incremental power requirement.
 All streams between PNCP and refinery will be considered at fixed flow rates and at a
fixed price. C7-C8, PFO, C4 and PX feed Naphtha are considered as feedstock purchases.
C9 stream from PNCP is to be routed to second stage HDS section of existing Prime-g. C5
stream is considered as feed to the existing Isomerization unit.
 RFCC and DCU off gas will be routed to Ethylene Recovery facility in PNCP and fuel
gas after recovery will be returned to refinery.
 Propylene recovery to be considered and Polymer grade propylene from refinery will be
routed to PNCP for poly propylene production.
 Naphtha produced in refinery will be routed to PNCP for use as feedstock.
 All new facilities coming up under expansion fuel firing to consider RLNG + Internal fuel
gas as fuel. Also IFO firing in all existing refinery and PX-PTA heaters to be replaced by
RLNG firing in expansion case. Cost, if any, for this modification will be informed by client
for inclusion in FR.

New flare stack is demountable.
1.3.6 Plant Fuel/Hydrogen unit feed and fuel
For expansion cases, internal plant fuel requirement shall be met from fuel gas and RLNG.
Liquid fuel oil shall not be considered for fuel. Cost of replacement of liquid fuel to RLNG in
existing refinery will be provided by client for inclusion in cost estimates.
RLNG shall be considered as feed and fuel for the new hydrogen generation unit.
1.3.7 Auxiliary Units
a. HGU
Post saturation of existing HGUs, a new hydrogen generation unit based on naphtha or
RLNG as both feed and fuel is been considered for meeting the additional hydrogen
demand. RLNG and naphtha in any proportion can be used as feed to reformer in all the
three existing hydrogen generation unit. PREP HGU 76, 77 can use only naphtha as fuel.
b. Sulfur Block
Additional sour water and sour gas generation due to high sulfur crude under expansion
projects warrant incremental sulfur removal which shall be met by new Sulfuric Acid
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 15 of 39
production unit post saturation of existing SRUs. However, owing to no demand of sulphuric
acid, instead of sulphuric acid plant, sulphur recovery unit was considered subsequently.
1.4 Refinery configuration: LP model development
A feasibility study for BS VI fuel quality upgradation of IOCL Panipat Refinery at 15 MMTPA
was conducted by M/S EIL in March, 2016. This BS VI model is utilized as base case model
and then several configuration cases are built based on Licensor inputs and in-house
databank available with EIL for refinery capacity augmentation to 25 MMTPA. The results
were generated for each case considering the project objectives as well as utilization of the
existing refinery facilities.
These results were then evaluated and analyzed for their respective economic benefits.
Gross Refining Margins (GRM), simple payback period and operational feasibility are used
for comparative analysis and short listing of the various options have been studied.
1.4.1 Major considerations for the base case are as follows:
 BS VI project is considered as executed for the expansion case study. Hence
the following facilities are considered as available:
Table 1.4.1.1
Unit
Capacity (Design)
DHDT
2200 KTPA
HGU
44 KTPA
Sour water Stripper (2 stage)
56.7 m3/hr
ARU (MDEA based)
189 TPH
SRU + TGTU
225 TPD
 100% BS VI fuels production.
 SOx have been limited to 1000 Kg/hr (excluding PXPTA/PNCP).
 Naphtha from refinery to PNCP shall be minimum 60% of 2910 KTPA (1746 KTPA) of
the total naphtha requirement in PNCP (2910 KTPA). This naphtha sales from refinery shall
be evaluated at 3 year avg price. Fuel gas from RFCC and DCU to be routed to PNCP for
ethylene recovery at fuel gas price.
 There is no production of Premium gasoline for base case due to less price differential
between regular and premium MS.
 For all the existing and new units, number of stream hours will be 8000hrs/yr.Price of
PFO from PNCP shall be considered as same as price of high sulphur fuel oil.

Aromatics of C7-C8 stream from PNCP updated to 75 vol%.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 16 of 39
 RON, RVP and aromatics for Prime G product updated to 87, 0.4 kg/cm2 A and 26 vol%
respectively in consultation with client.
 RON and RVP for isomerate updated to 87 and 1.0 kg/cm2 A in consultation with client.
 C-9 shall be routed only to prime G unit in order to saturate the revamped capacity of
Prime G. Bottom streams from new DCU light naphtha splitter located in revamped
Prime G is routed to HGUs.
 C7-C8 stream from PNCP to refinery shall be considered as 228 KTPA for base as well
as expansion cases.
 Paraffins in Full conversion hydrocracker light naphtha are same as that for paraffins in
OHCU light naphtha, i.e. 79 vol%.
 Sulfur in feed to be limited to following after discussion with client:
Table 1.4.1.2
UNITS
SULPHUR LIMITS (WPPM) IN
FEED
1
HGU-1
200
2
HGU-2
5900
3
HGU-3
5900
4
DHDS
17000
5
6
7
PREP DHDT
BS-VI DHDT
NHT FOR CCR
17300
18850
700
S.NO

Following limits in feed are to be maintained in DHDTs after discussion with client:
Table 1.4.1.3
S.NO
UNITS
COKER DIESEL
(wt% of feed )
RFCC DIESEL
(wt% of feed)
COKER NAPHTHA
(wt% of feed)
1
PREP DHDT
33
5.1
1.4
2
BS-VI DHDT
41.6
8.4
8.9
1.4.2 Configuration options studied for 25 MMTPA
Based on the above considerations and constraints, a comprehensive LP model was
developed to analyse the various configuration options for the refinery expansion to 25
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 17 of 39
MMTPA. A total of twenty configuration options were studied in detail covering total persona
of various secondary processing options and four options for bottom processing units.
1.4.2.1 Primary processing unit
Crude processing capacity enhancement realization by installation of new CDU/VDU of 10.0
MMTPA capacity.
1.4.2.2 Secondary processing Unit
EIL has considered the following secondary processing facilities:
 VGOHDT + INDMAX (low CCR) + PRU
 INDMAX (high CCR) +PRU
 Once through HCU + INDMAX (low CCR) + PRU
 Once through HCU + LOBS
 Full conversion HCU
1.4.2.3 Bottom Up-gradation facilities
EIL has considered the following options for upgradation of vacuum residue generated from
the refinery (post capacity expansion):
 Delayed Coker Unit
 Delayed Coker Unit + SDA
 Residue Hydroprocessing facility (with 90% conversion)

Residue hydroprocessing facility (with 70% conversion) is also considered for this study
Thus in all 20 different configuration options as the table below were analyzed for the
design crude mix.
Table 1.4.2.3.1- Configuration options analyzed
BOTTOM PROCESSING UNIT
SECONDARY PROCESSING UNIT
FULL CONVERSION HYDROCRACKER
INDMAX (low CCR) + PRU
INDMAX (high CCR) +PRU
DCU
VGOHDT + INDMAX (low CCR) + PRU
OHCU + INDMAX (low CCR) + PRU
OHCU + LOBS
FULL CONVERSION HYDROCRACKER
SDA+DCU
INDMAX (low CCR) + PRU
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 18 of 39
INDMAX (high CCR) +PRU
VGOHDT + INDMAX (low CCR) + PRU
OHCU + INDMAX (low CCR) + PRU
OHCU + LOBS
FULL CONVERSION HYDROCRACKER
INDMAX (low CCR) + PRU
RESIDUE
HYDROPROCESSING
FACILITY (90%
CONVERSION)
INDMAX (high CCR) +PRU
VGOHDT + INDMAX (low CCR) + PRU
OHCU + INDMAX (low CCR) + PRU
OHCU + LOBS
FULL CONVERSION HYDROCRACKER
INDMAX (low CCR) + PRU
RESIDUE
HYDROPROCESSING
FACILITY (70%
CONVERSION)
INDMAX (high CCR) +PRU
VGOHDT + INDMAX (low CCR) + PRU
OHCU + INDMAX (low CCR) + PRU
OHCU + LOBS
1.4.3 REFINERY CONFIGURATION SCREENING
The results of the LP model were generated for the configuration options listed above. The
analysis of these options studied is summarized below –
Table 1.4.3.1
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
TOTAL
PROJECT
COST (RS CR)
SIMPLE
PAYBACK
(YEARS)
CASE AB3
CASE AB4
CASE AB5
DCU+OHCU+ INDMAX
LOW CCR+LOBS
SDA+DCU+FCHCU
SDA+DCU+INDMAX
HIGH CCR+PRU
SDA+DCU+VGOHDT+I
NDMAX LOW
CCR+PRU
SDA+DCU+OHCU+IN
DMAX LOW
CCR+PRU
SDA+DCU+OHCU+IN
DMAX LOW
CCR+LOBS
90% CONV+FCHCU
90% CONV+INDMAX
HIGH CCR+PRU
70% CONV+FCHCU
70% CONV+INDMAX
HIGH CCR+PRU
12114
11392
12241
12594
12969
12114
11392
12241
12594
12969
13176
13022
13327
13605
14001
14779
14533
14845
15062
7.4
10
9.4
10.1
10.4
10.7
10
9.4
10.1
10.4
10.7
10.9
10.8
11
11.3
11.6
12.2
12.0
12.3
12.5
20239 24344 25589 24160 24660 20239 24344
3.0
Template No. 5-0000-0001-T2 Rev. 1
4.1
3.8
3.4
3.3
3.0
4.1
25589
24160
24660
3.8
3.4
3.3
26242 32759
3.4
4.3
33522
32550
4.3
4.0
3.9
2.8
3.8
33090 26517 34652 35188
3.8
70%CONVERSION+
OHCU++LOBS
70%CONVERSION+V
GOHDT+INDMAX
LOW CCR+PRU
70%
CONVERSION+OHCU
+INDMAX LOW
CCR+PRU
90%CONVERSION+V
GOHDT+INDMAX
LOW CCR+PRU
90%
CONVERSION+OHCU
+INDMAX LOW
CCR+PRU
90%CONVERSION+O
HCU+INDMAX LOW
CCR+LOBS
CASE AB2
DCU+OHCU+INDMAX
LOW CCR+PRU
5448
CASE AD5
CASE AD4
CASE AD3
CASE AD2
CASE AD1
CASE AC5
CASE AC4
CASE AC3
CASE AC2
CASE AC1
CASE AB1
CASE AA5
CASE AA4
CASE AA3
CASE AA2
DCU+VGOHDT+INDM
AX LOW CCR+PRU
CASE AA1
DCU+INDMAX HIGH
CCR+PRU
GRM
(US$/ BBL)
DCU+FCHCU
GRM
(Rs Crore/
Annum)
BASE CASE FOR 25
MMTPA STUDY
Executive Summary
Feasibility study for
capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0
MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 19 of 39
15439
12.8
32213
32395
3.4
3.2
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 20 of 39
Based on the results presented in the section above, following points are noted:

No limit on RLNG import is to be considered. Also, internal fuel oil made open based
on economics.

It was observed that SDA unit requires more hydrogen, so LP model prefers to process
the vacuum residues directly in bottom processing units: DCU, Ebullated bed and slurry
hydrocracker rather than having a 30wt% lift upstream of these bottom processing units.
Based on economics, SDA unit is found to be not economical..

CCR in existing DCU is to be maintained at 25 wt%.

Cracked feed to OHCU and HCU is maintained within 20wt% of total feed to maintain
nitrogen limit in the feed.

Slop from VDUs is not routed to existing HCU’s because of limitation on arsenic and
other metals in feed to these units.
 DCU light naphtha is routed to new splitter in revamped Prime G unit, and DCU heavy
naphtha is routed to DHDT unit.
 OHCU heavy naphtha may be routed to CCR. Full conversion HCU heavy naphtha is to
be routed to diesel.

OHCU/ FC-HCU light naphtha is not be routed to ISOM.
 Minimum density specification for BS-VI Diesel is to be removed in line with latest BS-VI
gazette notification from govt.
 HGU’s (existing and new) can be operated on naphtha or RLNG feed, whichever is
economical. RLNG and naphtha in any proportion can be used as feed to reformer in all
three hydrogen generation unit. HGU 76, 77 can use only naphtha as fuel.

All GT’s to be operated only on RLNG feed.

OHCU revamp to 2.4 MMTPA capacity with 4 drum system to be considered.
 Since the price of RLNG provided is high, eliminating internal fuel oil (max sulphur of
0.5 wt.%) will lead to drop in GRM for expansion cases. Hence replacement of entire
refinery fuel to refinery fuel gas and RLNG is not be considered.

Prices considered are based on 3 year Avg price (1st April 2014-31st March 2017).

It was decided not to consider DCU in the expansion cases.

PPU along with PRU to be considered in expansion cases to boost GRM.
 Internal Fuel oil make in expansion cases is based on economics (based on price of
RLNG).
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 21 of 39
 Separate new Kero HDS has not been considered in order to restrict cracked feed % to
new DHDT unit
 IOCL informed that in absence of any demand of H2SO4 in Panipat region, EIL to
consider production of sulfur in all expansion cases.
 For OHCU+LOBS case the capacity of LOBS unit was capped at 500KTPA. Only
OHCU bottoms are used as feed to LOBS unit. In order to accommodate remaining OHCU
bottoms an Indmax unit was considered. But the capacity of Indmax unit was very small,
which was uneconomical, hence the capacity of LOBS unit was increased from 500 to 1000
KTPA.
Hence, configuration study shall be done on 10 cases with 5 secondary processing options
and 2 bottom processing options of 90% and 70% bottom hydro processing units. Results
and analysis for ten LP case is as follows:
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 22 of 39
Table 1.4.3.2
90%
90%CONVE
CONVERSI
RSION+OH
ON+OHCU+I
CU+INDMA
NDMAX
X (LOW
LOW
CCR)+LOBS
CCR+PRU+
+PPU
PPU
70%
CONV+FCH
CU
70%
CONV+IND
MAX HIGH
CCR+PRU+
PPU
70%CONVE
RSION+VG
OHDT+IND
MAX LOW
CCR+PRU+
PPU
14998.1
14948.4
17356.8
16996
16168.6
16167
12.4
12.4
12.4
14.4
14.1
13.4
13.4
28152.6
27257.1
28226.3
22677.5
28848.3
29364.2
26979
27615.1
2.8
2.9
3
2.4
2.4
2.5
2.5
2.6
90%
CONV+FC
HCU
90%
CONV+IND
MAX HIGH
CCR+PRU+
PPU
90%CONVERS
ION+VGOHDT
+INDMAX
LOW
CCR+PRU++P
PU
GRM (RS
CR/A)
13174.8
15714.2
15407.8
14989.5
GRM
(US$/BBL)
10.9
13
12.7
TOTAL
PROJECT
COST (RS
CR)
22322.5
27578.3
SIMPLE
PAYBACK
(YEARS)
2.9
2.7
Template No. 5-0000-0001-T2 Rev. 1
70%CON
VERSIO
N+OHC
U+INDM
AX
(LOW
CCR)+L
OBS+PP
U
70%
CONVERSI
ON+OHCU+I
NDMAX
LOW
CCR+PRU+
PPU
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 23 of 39
1.4.4 Observations
 However, it was observed that the total project cost for these cases was very high. A
decision was reached to change the design crude mix. New design crude mix considered
will be same as Base Case crude mix except for substitution of 0.5 MMTPA of Mangla
crude with equivalent quantity of Dalia crude. This revised crude mix is low in sulphur and
lighter. However, objective for optimization for expansion case shall be same as considered
for earlier design case crude mix.
 IOCL informed that ethylene recovery from new units shall not be considered. IOCL
confirmed that the ethylene rich fuel gas is to be considered as fuel to expanded refinery
and shall not be considered as export to PNCP for ethylene recovery.

Owing to low hydrogen demand Kero HDS unit was considered.
Graphical representation of New design crude mix:
Fig. 1.4.4.1
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 24 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Results and analysis for ten configuration cases with change in design crude mix is as follows:
Table 1.4.4.1
90%
70%
90%CONVE
70%CONVE
REVISED
90%
CONVERSI
70%
CONVERSI
RSION+VG
RSION+VG
BASE
90%
CONV+IND
ON+OHCU 90%CONVE
70%
CONV+IND
ON+OHCU 70%CNVER
OHDT+IND
OHDT+IND
CASE FOR CONV+FCH MAX HIGH
+INDMAX RSION+OH CONV+FCH MAX HIGH
+INDMAX SION+OHC
MAX LOW
MAX LOW
25 MMTPA
CU
CCR+PRU+
LOW
CU+LOBS
CU
CCR+PRU+
LOW
U+LOBS
CCR+PRU+
CCR+PRU+
STUDY
PPU
CCR+PRU+
PPU
CCR+PRU+
PPU
PPU
PPU
PPU
CASE NO.
Case BA1
Case BA2
Case BA3
Case BA4
Case BA5
Case CA1
Case CA2
Case CA3
Case CA4
Case CA5
13522.8
13265.5
12854.9
12150.8
12732.2
14303.9
14423.0
13905.5
13747.5
GRM (RS
CR/A)
5448.8
11434.7
GRM
(US$/BBL)
7.4
9.3
11.0
10.8
10.5
9.9
10.4
11.7
11.8
11.3
11.2
TOTAL
PROJECT
COST (RS
CR)
18195.8
21013.4
23230.3
22465.2
21283.3
20046.0
21773.6
24646.2
23487.6
23827.7
SIMPLE
PAYBACK
(YEARS)
3.0
2.6
3.0
3.0
3.2
2.8
2.5
2.8
2.8
2.9
1.4.5 Shortlisting of Two Cases
Based on the above analysis following two cases were shortlisted:
 LP Case No. BA1 and LP Case No. CA1 were eliminated since there is no
petrochemical production potential for these configurations.
 LP Case No. BA2 and LP Case No.CA2 were eliminated since for these configurations,
Indmax unit is operating on straight run VGO and VR without any treatment (upto feed CCR
limit of 6 wt% and feed total nitrogen limit of 1800 wppm). Hence these cases do not give
flexibility in crude selection. A small variation in crude quality may result in wide variation in
yields and product properties of the Indmax unit, which will directly affect the refinery
margin.
 Moreover, SOx and NOx emissions from Indmax is high for these cases. Hence, flue
gas desulphurizer is additionally considered and hence control on SOx and NOx emissions
from Indmax unit is difficult.
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 25 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
 LP Case No. BA4 and LP Case No. CA4 were eliminated since for these configurations,
OHCU (with 70% conversion) is reducing feed to downstream Indmax unit. Hence poly
propylene production in these cases is lower, which results in lower refinery margin.
 LP Case No. BA5 and LP Case No.CA5 were eliminated since there is no
petrochemical production potential for these configurations. Panipat refinery is already
petrochemical oriented (with adjoining PNCP) and adding another dimension to it with
LOBS production was not felt to be desirable.
Following two cases were shortlisted for IRR calculations:
1. Shortlisted Case 1 - LP Case BA3
2. Shortlisted Case 2 - LP Case CA3
Based on the following discussions:
 With VGO HDT upstream of Indmax unit, these configurations provide crude selection
flexibility.
 Due to maximum production of propylene, these configurations offer high refinery
margin.
 Since feed to Indmax unit is hydrotreated in upstream VGOHDT, SOx and NOx
emissions from Indmax unit are in reasonable limit.
 Estimated preliminary capex is high, but due to high margins, these cases offer similar
payback periods as for rest of the cases.
1.5 Material Balance
Refinery material balance for two shortlisted cases is as follows.
Table 1.5.1 - Feedstock purchases (KTPA) for shortlisted cases
FEEDSTOCK PURCHASES
CRUDE BLEND
CRUDE BLEND
LNG IMPORT
MATHURA REFINERY
NAPHTHA
SURPLUS H2 AVAILABLE
FROM PNCP
C4 FROM PNCP
C5 FROM PNCP
C7-C8 FROM PNCP
C9+ STREAM FROM PNCP
FUEL OIL FROM PNCP
METHANOL TO TAME UNIT
Template No. 5-0000-0001-T2 Rev. 1
reserved
BASE CASE FOR 25
MMTPA STUDY
SHORT LISTED
CASE-1
SHORT LISTED
CASE-2
15000.0
0.0
1067.5
0.0
25000.0
1581.5
0.0
25000.0
1944.5
150.0
150.0
150.0
6.8
6.8
6.8
200.0
170.0
228.0
100.0
112.0
9.6
200.0
170.0
228.0
100.0
112.0
8.3
200.0
170.0
228.0
100.0
112.0
9.2
Copyright EIL – All rights
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
PRODUCT SALES
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 26 of 39
Table 1.5.2- Product Sales (KTPA) for shortlisted cases
BASE CASE
SHORT LISTED
SHORT LISTED
FOR 25 MM
CASE-1
CASE-2
TPA STUDY
MIXED LPG'S
635.9
1568.1
1517.1
POLY PROPYLENE
NAPHTHA TO PNCP
BS-VI REGULAR
GASOLINE
BS-VI PREMIUM
GASOLINE (% of Total
Gasoline)
BS-VI HSD
BENZENE
PTA
ATF
HIGH SULPHUR FUEL
OIL
BITUMEN
COKE
RESIDUE
HYDROPROCESSING
PITCH
PRODUCT SULPHUR
0.0
1970.4
533.5
1746.0
528.2
1746.0
1688.2
3895.5
3827.2
0
305.6 (7.3)
7733.8
24.6
700.0
1125.0
12844.6
24.6
700.0
1500.0
13150.8
24.6
700.0
1500.0
225.0
0.0
0.0
360.0
908.9
360.0
867.0
360.0
867.0
0.0
162.7
0.0
142.4
374.9 TPD
393.7 TPD
17045.7
565.5 (12.9)
1.6 Unit Capacities of new units
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
17543.5
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 27 of 39
Table 1.6.1
CAPACITY FOR
SHORTLISTED CASE 1
CAPACITY FOR
SHORTLISTED CASE
2
UNIT
UOM
CDU / VDU
MMTPA
10.0
10.0
PRU
KTPA
1136.4
1157.0
PPU
KTPA
537.7
547.3
NHT
MMTPA
1.4
1.6
CCR
MMTPA
0.7
0.8
ISOM
MMTPA
0.8
0.8
DHDT
MMTPA
1.2
1.3
KERO HDS
MMTPA
2.7
2.7
VGO-HDT
MMTPA
2.4
2.4
INDMAX
MMTPA
2.6
2.6
90% CONVERSION
MMTPA
2.0
0.0
70% CONVERSION
MMTPA
0.0
3.2
HYDROGEN
GENERATION UNIT
KTPA
45.0
67.0
TPD
555.0
630.0
SULPHUR
RECOVERY UNIT
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 28 of 39
1.7 Total Project Cost
Table 1.7.1
SHORT LISTED
CASE-1
Units
Capital Cost (Rs Crore)
SHORT LISTED
CASE-2
22621.93
23994.20
1.8 Financial Results
Table 1.8.1
S No
Description
Short Listed Case-1
(Rs crores)
Short Listed Case-2
(Rs crores)
1
Capital Cost
22621.93
23994.20
2
Variable Operating Cost
31362.77
32055.49
3
Fixed Operating Cost
411.61
434.13
4
Total Operating Cost
31774.37
32489.62
5
Sales Revenue
38503.50
40290.22
6
IRR (Pre Tax) on Total Capital
22.13%
23.57%
7
IRR (Post Tax) on Total Capital
18.01%
19.08%
8
IRR (Pre Tax) on Total Equity
26.81%
28.79%
9
IRR (Post Tax) on Total Equity
21.40%
22.93%
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 29 of 39
1.9 Financial Parameters
Table 1.9.1
1
Construction Period
36 Months
2
Project Life
25 years
3
Debt / Equity Ratio
50:50
4
Expenditure Pattern
Equity before debt
5
Loan Repayment period
10 years
6
Moratorium Period
2 Year
7
Interest on Short Term Loan
9.35%
8
Capacity Build – up
1st year
60%
2nd year
80%
3rd year onwards
100%
9
Corporate Tax Rate
34.61
10
MAT
21.34
1.10
Observations and Inferences
Based on the results presented in the section above and basis adopted for study, following
points are concluded:
 Shortlisted case 2 has Superior Internal Rate of Return (IRR) as compared to
shortlisted case 1

Project Capital Cost for shortlisted case 2 is comparable to the other short listed case.
 No generation of Hydro processing Pitch to be disposed in shortlisted case 2having
70% bottoms hydroprocessing unit as unconverted oil of 70% conversion unit is fed to
existing DCU.
 Yields of distillate products (MS+HSD) obtained is higher than (around 2%) in
shortlisted case 2 than the corresponding yield obtained in the other shortlisted case.
 Hence, based on the above observation shortlisted case 2 i.e was the recommended
case for this configuration study.
However, following modifications were proposed:
 Owing to low anticipated demand of polypropylene product the production of
Polypropylene was restricted to 450 KTPA.
 Concern was also raised about the demand of MS in future. Decision was taken to limit
MS production at 3800 KTPA.
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 30 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL

Demand of ATF was increased to 2000 KTPA.
 Minimum limit of Panipat Naphtha to PNCP was increased to 2200 KTPA from previous
limit of 60% of 2910 KTPA i.e 1746 KTPA.
 Recommended case to be updated to produce minimum 25% and maximum possible
Premium gasoline by installation of an alkylation unit.
 In order to have adequate margins in the HGU and SRU capacities in the
recommended case higher sulfur content of typical crude 2.2 wt.% instead of 1.8 wt.% is to
be considered. .
 It was suggested that up to propylene storage shall be considered in refinery area of P25. New PPU shall be located in PNCP area as space of one train of PPU is already
available in PNCP area. Propylene shall be pumped from refinery to new PPU in PNCP
area. All associated utilities/offsite/warehouse requirement for New PPU shall be part of
PNCP area. IOCL has provided plot plan for PNCP.
 Base case considered for this study was based on BS VI feasibility study report. Even
with the installation of a new TAME unit it was observed that there was no production of
premium grade gasoline in the base case. Hence base case was modified to produce
premium grade gasoline.
1.11
Selected case
1.11.1 Material Balance
Table 1.11.1: Feedstock Purchases (KTPA)
FEED
QUANTITY
CRUDE BLEND
25000.0
LNG IMPORT
C7-C8
1447.6
228.0
C9+ STREAM
100.0
FUEL OIL FROM PNCP
112.0
C4 FROM PNCP
C5 FROM PNCP
200.0
170.0
SURPLUS H2 AVAILABLE FROM PNCP
6.8
MATHURA REFINERY NAPHTHA
150.0
METHANOL TO TAME UNIT
9.6
Table 1.11.2: Product Sales (KTPA)
PRODUCTS
QUANTITY
MIXED LPG'S
725.3
POLY PROPYLENE
450.0
PROPYLENE FROM EXISTING
REFINERY
110.7
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 31 of 39
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
FUEL GAS FROM EXISTING
REFINERY
POLYMER GRADE PROPYLENE
BS-VI PREMIUM GASOLINE
BS-VI REGULAR GASOLINE
BENZENE
PTA
TOTAL NAPHTHA TO PNCP
ATF
BS-VI HSD
BITUMEN
COKE
PRODUCT SULPHUR
84.8
0.0
3515.5
284.5
24.6
700.0
2735.8
2000.0
12756.6
360.0
867.0
367.5
Table 1.11.3: Capacity of New units (KTPA)
UNIT
UNIT CAPACITY
CDU/VDU
10000.0
VGO HYDROTREATER
2199.3
DHDT-4
685.3
PROPYLENE SEPARATION UNIT
985.7
INDMAX
2207.8
NEW KERO HDS
2656.6
NHT FOR CCR AND ISOM
829.8
NEW CCR
624.1
NEW ISOM
201.1
NEW PPU
450.0
ALKYLATION UNIT
669.4
70% BOTTOM HYDROPROCESSING UNIT
2771.2
SULPHUR RECOVERY UNIT
2X324
HYDROGEN GENERATION UNIT
65.0
1.12
Utilities
For the utilities estimation for the selected case following points were noted:
 Since the proposed secondary units for 25 MMTPA shall come up at a new location,
new utility systems are envisaged. The utilities required for recommended case are given
below. Post BS-VI at 15.0 MMTPA, no margin is available in existing utility systems- cooling
water, compressed air (PA, IA and nitrogen) etc. Nitrogen is not available from existing
BOO compressor, hence nitrogen requirement for P-25 shall be met from new N2 plant.
 Existing steam generation systems are just adequate post BS-VI at 15.0 MMTPA
refinery capacity. Hence, for steam consumption of new facilities required for expansion
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 32 of 39
from 15.0 MMTPA to 25.0 MMTPA, new steam systems shall be considered.
 Untreated raw water for P-25 shall be supplied from existing reservoir. However, raw
water treatment and treated raw water reservoir (for 8 hours of storage) shall be considered
for P-25.
 Fire water system/network including fire water reservoir (for 8 hours of storage) shall be
considered for P-25.
 Post BS-VI at 15.0 MMTPA, no margin is available in existing ETP.
 Post BS-VI at 15.0 MMTPA, no margin is available in existing Flare system.
 Post BS-VI at 15.0 MMTPA existing steam generation systems are just adequate. For
steam consumption of new facilities required for expansion from 15.0 MMTPA to 25.0
MMTPA, new steam systems shall be considered.
Table 1.12.1 Utility Requirements
Unit of
Unit Name
Measure
Selected case
Utility System
Raw Water System
m3/hr
3000
3
Cooling Water System
m /hr
60000
3
Condensate Polishing Unit
m /hr
205
Utility Boiler – VHP Steam
TPH Steam
300
Utility Boiler – HP Steam
TPH Steam
160
3
Compressed Air (IA/PA) System
Nm /hr
26200
Nitrogen Plant
Capacity
7600 Nm3/hr
Flare
Stack Sizes &
56” (Hydrocarbon), 16” (Sour) &
Height
150m height
Effluent Treatment Plant (Zero
For treating Oily Water, Sanitary
Liquid Discharge achieved through
Effluent and CRWS along with
consideration of Evaporator and
Spent Caustic, Boiler Blowdown
Crystallizer)
and CW Blowdown
1.12.1 Raw water system A Raw water treatment plant of capacity 3000 m3/hr is considered
for the refinery expansion. Raw water post treatment is put to the following uses:
 Cooling water make-up
 Service water
 Fire water
 Feed to ETP plant
Cost of raw water is taken as Rs. 13.49 per m3.
1.12.2 Cooling water system: Cooling Tower system with cells (16W+1S), each of capacity
4000 m3/hr has been considered for the selected cases, to meet the cooling water requirement
mentioned in Table above.
1.12.3 Steam, power, BFW and DMW:
Steam Requirement:Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 33 of 39
Two utility boilers: 1 VHP boiler with a capacity of 300 Tons/h and 1 HP boiler with a
capacity of 160 Tons/h has to be installed to meet the steam requirement of the new units.
Power Requirement:Power import from grid is envisaged to meet the power requirements of new units. All
associated utilities requirement for New PPU shall be met from the PNCP area. Power
requirement for the selected case is 71 MW. Additional Power requirement of the new PPU
is 20.5 MW.
BFW Requirement:BFW generation of 208.2 TPH has been considered for the selected case to meet BFW
requirement.
DM Water: - In order to have zero liquid discharge from the refinery ETP plant will be
considered for the selected case to meet DMW requirement.
1.12.4 Condensate Polishing Unit: A CPU has been considered to polish condensate
generated from new units. A CPU of 205 m3/h is considered for the selected case.
1.12.5 Fired Duty: The Fuel requirement for the new units envisaged in this study would be
met by imported RLNG. Fuel oil, fuel gas and naphtha generated internally from the various
new units are also used as fuel.
1.12.6 Compressed Air and Nitrogen System: The requirement of IA/ PA and N2 for present
study is 26200 Nm3/h and 7600 Nm3/h respectively. A suitably sized compressed air and
nitrogen system to cater to the same is provided.
1.13 Flare
New demountable flare system with 56” diameter flare stack for hydrocarbon along with
water seal drum, fuel gas KOD , flare KOD and flare KOD pumps has been considered.
The height of the flare stack has been considered as 150 m. With this height, the radiation
level outside 90 m radius circle around flare stack shall be within the allowable limits.
New Acid Gas flare shall be required for handling sour gases. Sour gases to be flared shall
be collected in a 16” pipe header connected to Acid gas KOD. Sour gases after KOD shall
be routed to flare stack of diameter 16” and height 100m with a dedicated burning tip.
1.14 Effluent Treatment Plant
Cost provision for an ETP of 500 m3/hr capacity has been considered for the selected case.
1.15 Offsite Systems
The existing refinery is well connected with crude and product pipelines for receipt and
dispatch of crude and products respectively. The refinery is also equipped with a tank farm
which caters to the current refinery throughput. However, based on 25.0 MMTPA study
some of the existing facilities need augmentation. The offsite facilities required are given
below. Infrastructure cost for additional crude receipt and additional product evacuation: the
cost due to this is not required to be considered under this study.
For offsite tank calculation, following philosophy to be adopted:
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 34 of 39
 In case the required no. of days (4 for crude, 5 for intermediate products and 7 for
finished products) are not available for base case at 15.0 MMTPA, storage to meet the
shortfall shall not be provided under P-25.
 In case the no. of days (4 for crude, 5 for intermediate products and 7 for finished
products) are surplus for base case at 15.0 MMTPA, margin available shall be considered
for new tanks estimation for P-25.
 For crude storage, separate tanks shall be considered for low sulfur and high sulfur
crudes with 4 days of storage for each.
1.15.1
Tankages
The storage tanks have been estimated based on the following philosophy:

Crude tanks – No new tanks.
The existing crude oil tanks are sufficient to provide 4 days of storage for 25 MMTPA
capacity.

Product tanks- Total 7 days storage
The existing product storage is found to be adequate except for LPG, naphtha, MS and
Diesel products.Hence new storage tanks for the same are considered. Details are provided
below:
Template No. 5-0000-0001-T2 Rev. 1
reserved
Copyright EIL – All rights
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 35 of 39
Table 1.15.1.1: Liquid Products Storage
Tank No.s
No of Tanks
Height
(M)
POLY
PROPYLENE
LPG
Dia
(M)
Thickness
(m)
Geometric vol
(m3)
Storage
Vol /tank
(m3)
Approximate
empty weight
(Kg)/Tank
Type of
Tank
PELLETIZER AND STORAGE FACILITY FOR 9450 PELLETS (1 PELLET IS FOR 1 TON OF POLYPROPYLENE)
Mounded
8
0.047
4019
3215
736954
Bullets
1
80
Naphtha
MS
(PREMIUM)
1
16.0
45.1
0.03
25547
20438
530372
3
13.4
39.7
0.03
16579
13263
DIESEL
1
14.4
59.6
0.03
40154
32123
Class
Flash
Point
GAS
0.047
FR
A
< 23
391002
FR
A
< 23
630801
FR
B
~35
Table 1.15.1.2: Solid Products Storage
Solid products
POLY PROPYLENE
Template No. 5-0000-0001-T2 Rev. 1
PELLETIZER AND STORAGE FACILITY FOR 9450 PALLETS (1 PALLET IS FOR 1 TON OF
POLYPROPYLENE)
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL

Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 36 of 39
Intermediate Tanks
Accordingly, based on utilization of the existing tanks available for each service, additional storage tanks
required for intermediate feed streams has been estimated. Sulphuric acid storage is required for use in
Alkylation unit. Details are provided belowTable 1.15.1.3: Intermediate Tanks
Tank No.s
No.of
Tanks
Height (M)
Dia (M)
Thickness
(m)
Geome
tric vol
(m3)
Storage
Vol /tank
(m3)
Approxi
mate
empty
weight
(Kg)/Ta
nk
Propylene
7
80.0
8.0
0.047
4019
3215
736954
Type of
Tank
Class
Flash
Point
Mounded
Bullets
GAS
---
NHT feed
Reformate
Isom Feed
Isom Product
DHDT Feed
Kero HDS Feed
INDMAX Feed
INDMAX
Gasoline
2
1
1
1
1
2
2
14.0
14.0
10.0
11.0
14.4
14.4
14.2
31.6
35.6
26.2
18.0
35.1
51.5
39.5
0.03
0.03
0.03
0.03
0.03
0.045
0.03
10974
13928
5370
2803
13926
30008
17411
8779
11143
4296
2243
11141
24006
13928
325161
366321
192232
145674
371490
817969
412477
FR
CR
FR
FR
FR
FR
CR
A
A
A
A
B
B
C
< 23
< 23
< 23
< 23
~35
~35
>65
1
14.0
33.6
0.03
12425
9940
345988
FR
A
< 23
Alkylate Feed
1
80
8
0.047
4019
3215
736954
GAS
0.047
Alkylate Product
Fresh Acid
Spent Acid
1
1
2
14
10
10
38
8
6
0
0
0
15688
543
285
12550
434
228
388767
61126
44274
A
C
C
< 23
>65
>65
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Mounded
Bullets
FR
CR
CR
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 37 of 39
Table 1.15.1.4: Intermediate Pumps
SERVICE
NO. OF
OPERATING
PUMPS
NO. OF
SPARE
PUMPS
RATED
FLOW
(M3/HR)
HEAD (
m)
POWER
OF EACH
PUMP
(KW)
MOC
TYPE
PPU FEED
1
1
135.0
140.1
40.8
CS
vertical barrel
NHT FEED
1
1
175.5
98.7
53.1
CS
Centrifugal
CCR FEED
1
1
131.8
98.7
39.9
CS
Centrifugal
REFORMATE
1
1
111.5
93.4
33.7
CS
Centrifugal
ISOM FEED
1
1
43.0
98.7
13.0
CS
Centrifugal
ISOM PRODUCT
2
2
38.9
93.4
11.8
CS
Centrifugal
DHDT FEED
1
1
125.4
84.4
37.9
CS
Centrifugal
KERO HDS FEED
1
1
480.1
84.4
145.3
CS
Centrifugal
VGOHDT FEED
2
2
402.5
84.4
121.8
CS
Centrifugal
INDMAX FEED
INDMAX
GASOLINE
2
2
385.1
81.5
116.5
CS
Centrifugal
1
1
99.4
93.4
30.1
CS
Centrifugal
70% CONV. FEED
1
1
475.6
77.8
143.9
CS
Centrifugal
Alkylate Product
1
1
125.5
87.6
38.0
CS
Centrifugal
Fresh Acid
1
1
5.4
38.1
1.6
CS
Centrifugal
Spent Acid
1
1
5.7
38.1
1.7
CS
Centrifugal
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
1.16
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 38 of 39
Land requirement
All the facilities except Polypropylene unit and polypropylene storage, proposed under the
study shall be located in the new plot identified by IOCL .Since, land is already available
with IOCL no cost towards procuring the land has been considered while estimating capital
cost.
1.17 Roads and Buildings
Buildings or extension of existing buildings has been considered to cater to the
requirement of increased manpower.
1.18 Manpower requirement
With the implementation of 25 MMTPA project, the complexity of the existing refinery will
increase. Therefore, to strengthen the organization, it is recommended to have manning
levels to reflect an effective operations and maintenance that would be required to support
the normal operation of the refinery. For this, adequate additional manpower strength in
various categories is considered.
1.19 Capital cost
The capital cost (with ±30%) for the selected case is tabulated below:
Table 1.19.1 capital cost for the selected case
Units
Selected case
Capital Cost (Rs Crore)
22900. 31
1.20 Financial analysis
Based on capital cost, operating cost and sales revenue, financial analysis has been carried out
to calculate Internal Rate of Return (IRR) and other financial parameters with a view to
establish the viability of the project.
For economic analysis, the current refinery product slate established by the LP model has been
considered. The sales realization as obtained for the refinery post 25.0 MMTPA has been
worked out. The parameters for performing financial analysis are tabulated below.
Table 1.20.1 Financial Analysis for the selected case
S.No.
Case
Selected case (Rs crores)
1
Capital Cost
22900.31
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Executive Summary
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 1,Page 39 of 39
2
Variable Operating Cost
30309. 83
3
Fixed Operating Cost
418 .68
4
Total Operating Cost
30728 .51
5
Sales Revenue
36612. 79
6
IRR (Pre Tax) on Total Capital
18.81%
7
IRR (Post Tax) on Total Capital
14.93%
8
IRR (Pre Tax) on Total Equity
22.17%
9
IRR (Post Tax) on Total Equity
17.00%
1.21
Environmental considerations
The SOx from the refinery complex (excluding PX-PTA complex) is limited at 1000 Kg/h..
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Introduction
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 2,Page 1 of 4
CHAPTER 2
INTRODUCTION
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 2,Page 2 of 4
Introduction
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
2.0
INTRODUCTION
Indian Oil Corporation Limited (IOCL) operates 15.0 million metric tons per annum
(MMTPA) refinery at Panipat in the state of Haryana, India.
Panipat refinery was set up under two phases:

Phase-I: PR- Panipat Refinery (Design capacity = 6.0 MMTPA)
Phase-II: PREP- Panipat Refinery Expansion Project (Design capacity = 6.0
MMTPA)
Through progressive revamps and addition of process units the refining capacity has
been brought to the present operating capacity of 15.0 MMTPA under PRAEP- Panipat
Refinery Additional Expansion Project. IOCL Panipat is also integrated with Naphtha
Cracker and Aromatic Complex.
With the objective to meet the guidelines established in Auto Fuel Policy 2025 wherein it
is required to manufacture 100% BS-VI fuels by 2020, 100% BS-VI project
implementation is currently under progress at refinery.
The existing refinery consists of following unitsTable 2.1: List of Existing Units
PANIPAT REFINERY – LIST OF PROCESS UNITS
PANIPAT REFINERY (PR) UNITS
S.NO.
UNIT NAME
UNIT NO.
LICENSOR
1.
CDU, VDU
2.
NSU-1 REVAMP
3
1.312 MMTPA
TECHNIP KTIL
3.
OHCU
5
1.9 MMTPA
UOP, IOCL
4.
HGU
6
38 KTPA
HALDAR TOPSOE
5.
RFCCU
7
0.85 MMTPA
SWEC,IOCL,EIL
6.
PSU
33
0.255 MMTPA
EIL
7.
CRU
8
IFP - AXENS
8.
DHDS
52
9.
VBU
9
0.64 MMTPA
0.55 MMTPA
(Based on BS VI FR)
0.4 MMTPA
10.
BBU
ATF MEROX (Converted
from Gasoline Merox)
LPG MEROX
10
0.5 MMTPA
EIL
12
30 m3/hr
UOP, IOCL, EIL
13
50 m3/hr
UOP, IOCL, EIL
15
180 m3/hr
22/44
115 TPD
15.
ATF-KERO MEROX
SRU/SSRU ( Common
Incinerator)
ARU
21
400 m3/hr
UOP
DELTA HUDSON
- EIL
EIL
16.
SWS-I (REFINERY)
17
71.8 m3/hr
EIL
11.
12.
13.
14.
Template No. 5-0000-0001-T2 Rev. 1
03, 04, 19
CAPACITY
7.5 MMTPA
EIL,IOCL
IFP - AXENS
EIL
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 2,Page 3 of 4
Introduction
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
SWS-II
18
(HYDROPROCESSING)
PANIPAT REFINERY EXPANSION (PREP) UNITS
16.4 m3/hr
17.
S. No.
UNIT NAME
EIL
UNIT NO.
CAPACITY
LICENSOR
73, 74
7.5 MMTPA
EIL
59
0.72 MMTPA
TECHNIP KTIL
1.
CDU, VDU
2.
NSU-2
3.
HGU
76, 77
2 X 70 KTPA
HALDER TOPSOE
4.
HCU
75
1.9 MMTPA
UOP
5.
DCU
78
3.0 MMTPA
ABB LUMMUS
6.
COKER LPG MEROX
79
0.1 MMTPA
UOP
7.
DHDT
72
3.5 MMTPA
AXENS
8.
SRU-I
55
225 TPD
BLACK & VEATCH
9.
SRU-II
56
BLACK & VEATCH
10.
TGU
57
11.
ARU
51
225 TPD
EQ.450 TPD
SULPHUR
410 m3/HR
3
BLACK & VEATCH
BLACK & VEATCH
12.
SWS-I (REFINERY)
53
170 m /HR
EIL
13.
SWS-II (HYDROPROCESSING)
54
40 m3/HR
EIL
PARA XYLENE AND PURIFIED TEREPHTHALIC ACID (PX and PTA) UNITS
CAPACITY
S.NO.
UNIT NAME
UNIT NO.
MMTPA
201,
1.
NHT, CCR
0.628
202, 203
2.
SHELL SULFOLANE
204
0.115
LICENSOR
UOP
UOP
3.
PAREX
205
2.494
UOP
4.
XFU
206
0.693
UOP
5.
ISOMAR
207
2.203
UOP
6.
TATORAY
208
0.624
UOP
7.
BTF
209
0.615
UOP
8.
PTA
221
DUPONT
9.
ERU
-
0.7
0.227 MMTPA
(Feed)
Thyssen Krupp
MS QUALITY UPGRADATION (MSQ) UNITS
S.NO.
1.
UNIT NAME
NHT /PENEX
UNIT NO.
301
2.
CAPACITY
410 / 400
TMTPA
470 TMTPA
RSU
302
FCC GDU
C9 stream PNCP shall be routed
3.
303
445 TMTPA
to second stage HDS of Prime G
unit. (100 KTPA).
PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT (PRAEP) UNITS
S.NO.
UNIT NAME
Template No. 5-0000-0001-T2 Rev. 1
UNIT NO.
CAPACITY
LICENSOR
UOP
IFP - AXENS
AXENS
LICENSOR
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 2,Page 4 of 4
Introduction
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
1.
SWS
20
2.
SRU-III
25
3.
TGU
26
40 m3/HR
225 TPD
EQ.450 TPD
SULPHUR
EIL
BLACK & VEATCH
BLACK & VEATCH
Under BS-VI project, following additional units are envisaged to be installedTable 2.2: List of BS-VI Units
BS-VI UNITS
S.NO.
UNIT NAME
UNIT NO.
CAPACITY
LICENSOR
1.
DHDT
-
2.2 MMTPA
UOP
2.
HGU
-
44 KTPA
-
3.
SRU
-
225 TPD
Prosernet
4.
TAME
-
36 KTPA
-
3
5.
ARU
-
189 m /hr
EIL
6.
SWS (Hydro processing)
-
56.7 m3/hr
EIL
In order to meet the demand growth of petroleum products and also to increase its
profitability and competitiveness in the long run, IOCL intends to enhance the refinery
capacity from 15.0 MMTPA to 25.0 MMTPA along with matching residue up gradation
unit, secondary processing unit, treating units, associated utilities and offsite.
IOCL has entrusted EIL to carry out the job of preparation of report for feasibility study
for capacity expansion from 15.0 MMTPA to 25.0 MMTPA. As base case for this
expansion, 100% BS-VI grade fuel production at 15.0 MMTPA has been considered.
In order to estimate the capital investment with an accuracy of ± 30% and to establish
the implementation plan for expansion, refinery configuration study & preparation of
report are performed by EIL based on their in-house expertise, in-depth process
knowledge, state-of the art tools, and years of their experience in the field.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Scope of Work
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 3,Page 1 of 5
CHAPTER 3
SCOPE OF WORK
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Scope of Work
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
3.0
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 3,Page 2 of 5
SCOPE OF WORK
The required scope of work for Panipat Refinery Expansion from 15.0 MMTPA to 25.0
MMTPA configuration study is as follows:
3.1 Refinery expansion





Carry out configuration study for the refinery considering capacity expansion from
15.0 MMTPA to 25.0 MMTPA.
Workout unit capacities and product slate for various configuration options for the
design crude mix.
Screening of various configuration options for the proposed capacity enhancement
and shortlisting of two configurations based on preliminary economics (GRM and
simple payback).
Carry out detailed analysis of shortlisted options. The detailed analysis of the short
listed options shall include the following
i. Developing overall material balance.
ii. Establishing product blending pools based on standard quality parameters
for each stream.
iii. Establishing additional utilities generation facilities required.
iv. Estimate / establish additional SOx and effluent generation & Fuel
requirement in comparison with existing 15.0 MMTPA refinery.
v. Capital cost estimate (within ± 30% accuracy) and financial analysis to select
most suitable configuration.
The most suitable configuration out of the shortlisted options will be the
recommended configuration. Following activities shall be carried out for the
selected configuration :
i. Developing the preliminary overall plot plan showing the location of the
expansion facilities.
ii. Developing schedule for the project.
iii. Feed/product specifications (feed blend, composition of each feed stream,
unit objective and product specifications) considered for study for all primary
and secondary units shall be included in the draft/final report.
The analysis and the final configuration shall incorporate the following considerations:







Crude processing capacity enhancement realization by installation of new
CDU/VDU of 10.0 MMTPA capacity.
Maximum utilization of existing unit capacities, utilizing design margins, as
available.
Residue upgradation facilities for the entire refinery to distillate products.
Downstream process facilities for meeting product quality specifications and other
requirements and to meet the environmental standards.
H2SO4 acid production for additional H2S produced.
Power import shall be considered for incremental power requirement. Only for
selected case, sensitivity shall be conducted for captive power production by LNG.
Zero liquid discharge from new facilities to be considered.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Scope of Work
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL

Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 3,Page 3 of 5
Zero production of Fuel Oil.
3.1.1 Bottom Up-gradation facilities
EIL shall consider following options for upgradation of vacuum residue generated from
the refinery (post capacity expansion):
 Delayed Coker Unit
 Delayed Coker Unit + SDA
 Residue Hydroprocessing facility (with 70% conversion)
 Residue Hydroprocessing facility (with 90% conversion)
3.1.2
Secondary Processing Unit
EIL shall consider the following secondary processing facilities:
 VGOHDT + INDMAX (low CCR) + PRU
 INDMAX (high CCR) +PRU
 Once through HCU + INDMAX (low CCR) + PRU
 Once through HCU + LOBS
 Full conversion HCU
3.1.3
Disposal of Excess Kerosene
Option of LAB plant, as a sensitivity case, shall be considered to minimize kerosene
production at 25.0 MMTPA crude throughput as a value added product.
3.1.4
Fuels Quality
Presently refinery at 15.0 MMTPA is capable to produce 100% BS-VI fuels.
Post capacity expansion, the entire auto fuels produced from the refinery after blending
shall meet BS-VI quality norms.
3.1.5
Crude Mix
Crude mix as indicated below shall be considered for the study:
Crudes
Bonny Lt.
Basrah Hy.
Kuwait
Maya
Saturno
Mangla
Iran mix
Arab mix
Base
Case
[MMTPA]
1.0
4.0
3.25
0.75
0
1.0
1.0
1.25
Template No. 5-0000-0001-T2 Rev. 1
Expansion Case [MMTPA]
Design
Check
Check
Case-1
Case-1*
Case-2*
0
2.5
0
8.1
7.1
0
12
14.2
13.5
0
0
5.7
3.7
0
4.6
1.2
1.2
1.2
0
0
0
0
0
0
Copyright EIL – All rights reserved
Scope of Work
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Crudes
Forcados
Escravos
Quaiboe
Zaffiro
Bombay High
TOTAL
Base
Case
[MMTPA]
0.5
0.5
0.75
0.5
0.5
15.0
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 3,Page 4 of 5
Expansion Case [MMTPA]
Design
Check
Check
Case-1
Case-1*
Case-2*
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
25.0
25.0
25.0
*For the selected configuration for 25.0 MMTPA, EIL will indicate only material balance,
GRM and achievable refinery throughput and unit throughputs for the check cases.
3.1.6 Plant Fuel/Hydrogen Unit Feed and Fuel
For expansion cases, internal plant fuel requirement shall be met from fuel gas and
RLNG. Liquid fuel oil shall not be considered for fuel. Cost of replacement of liquid fuel
to RLNG in existing refinery will be provided by IOCL for inclusion in cost estimates.
RLNG shall be considered as feed and fuel for the new hydrogen generation unit.
However, the unit will also be designed to handle naphtha as feed and fuel.
3.1.7 Storage Capacity Optimization
Storage capacity optimization for crude / intermediate and product tankage to be done
for the increased refinery capacity.
3.1.8 Miscellaneous
Other items to be specifically included in the scope are as under:
i. Following integration with PNCP will be considered:







All streams between PNCP and refinery will be considered at fixed flow rates and
at a fixed price.
RFCC and DCU off gas will be routed to Ethylene Recovery facility in PNCP and
fuel gas after recovery will be returned to refinery. Ethylene recovery from other
potential sources shall be considered in the scope of the study.
Propylene recovery shall be considered in the scope of the study and Polymer
grade propylene from refinery will be routed to PNCP for poly propylene
production.
Naphtha produced in refinery will be routed to PNCP for use as feedstock.
MEG, as required for value added PET production will be sourced from PNCP.
Excess Hydrogen produced in PNCP will be used in refinery. However, this
quantity shall not be considered while estimating capacity of new hydrogen unit.
Revamp cost towards PNCP expansion shall not be considered in the scope.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Scope of Work
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 3,Page 5 of 5
ii. Revamp cost towards 700 KTPA of PTA production shall not be considered in the
current scope.
iii. Modularization technology shall be considered wherever applicable to optimise
project scheduling and cost.
iv. PET will also be considered as value added product to improve IRR.
v. New flare stack shall be demountable.
vi. Flexibility to shift from HSD to gasoline maximisation and vice versa to be
considered.
vii. Unconventional energy to be maximised for non-critical area. To be studied.
viii. If more than two chain is required then combination of sulphur recovery unit and
H2SO4 production for additional H2S generated to be considered.
3.2 Cost Estimates
The accuracy of cost estimates will be ±30%.
3.3 Deliverables
EIL shall submit a draft report to IOCL upon completion of the scope of work as detailed
above.
Final report incorporating IOCL’s comments shall be submitted in 2 weeks. The final
deliverables shall be soft copy (PDF format) in addition to the 2 sets of hard copies.
3.4 Exclusions
Following are excluded from EIL’s scope of services:










Detailed design including hydraulic check, preparation of process
datasheets, updation of existing P&IDs, generation of P&IDs for new units
etc.
All items/considerations related to Basic Design/Detailed engineering stage.
Licensor selection for new units.
Market study.
Health check and condition assessment of the existing hardware.
Adequacy of / modifications in existing civil, structure, foundations, electrical,
instrumentation systems, MCR.
Adequacy of crude/ product pipelines.
Adequacy of marketing terminal.
Expansion/revamp study of PX-PTA.
Expansion/revamp study of PNCP.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion
of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
CHAPTER 4
BASIS OF STUDY
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 1 of 62
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 2 of 62
Basis of Study
Feasibility study for capacity expansion
of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
4.0 BASIS OF STUDY
The basis of study for the capacity expansion of Panipat Refinery from 15 MMTPA to 25 MMTPA
is provided in this chapter.
BASIC INFORMATION FOR PROJECT
Study to be Done by EIL

FR
Execution Methodology for Project (Not
Applicable)
Project Duration Required in Months
DFR
-
Other
-
LSTK
CONV
HYBRID
N/A
N/A
N/A
Not Applicable
Table 4.1
OTHER STUDIES
By EIL
By Others
Remarks
Market survey/study report
(Demand and supply
analysis)
Rapid Environmental impact
study
EIA and EMP study and data collection are excluded
from present scope
3
Site evaluation/selection
Existing refinery area
4
Evaluation/Selection of
licensors
Not in present scope. Will be done at subsequent stage.
5
Rapid Risk analysis
RRA study and data collection excluded from EIL scope.
6
Soil investigation
Not Applicable
Hydrological survey
Not applicable
Contour survey
Not applicable
1
2
Products limits are provided in the design basis by client
7
8
9
10
Route survey (for transport of
ODC materials from various
ports / industrial areas of the
country.)
Marine Survey-effluent
dispersion study
Health assessment
/inspection reports (For Revamp)
Downtime assessment report
(For Revamp)
Any other specific requirement
from Client
As per existing plant
Excluded from EIL scope
Excluded from EIL scope
Excluded from EIL scope
Sales and purchases of identified streams between
Refinery, and PNCP at the prices and limits identified by
client.
Basis of Study
Feasibility study for capacity expansion
of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 3 of 62
Table 4.2
PLANT LOCATION
Village
City
State
Nearest Railway
Station (kms)
-
Panipat
Haryana
Panipat
LAND AVAILABILITY DETAILS
Plot Area
1. Khasra Map,
Land Survey map
to be furnished.
As per
available data
with EIL
Length of connecting road
(between site and existing
main road). Kms
As per existing
plant
Rerouting Requirement
2.
Soil
investigation, site
details
like
Extent/cost of land
filling/ piling data, if
available may be
furnished.
As per
available data
with EIL
3. Land Rate (Rs per
acre)
N/A.
Plot
is
already available
at Refinery Site.
4. Land
availability
Road
380 acres of land
is available at
Panipat Refinery
site. For further
plot requirement,
shifting
of
Administration/
canteen / training
centre building to
CISF area to be
considered.
Rerouting of
facilities like
lines, drains
not required
details of the
furnished).
any existing
road, power
etc. required/
Not in present scope
(if required,
same may be
Met Data (By Customer)
Nearest
Distance
Grid Power
Availability
Level
As per existing
plant
Grid Power to be
considered
available for the
additional power
requirement due
to this expansion.
Sensitivity
of
selected
case
w.r.t.
power
supply shall be
done considering
captive power.
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 4 of 62
Table 4.3 : Raw Materials and Products
Raw Material
Name
Crude Mix
In KTPA
(Base
Case) 1. Natural Gas
Same as BS VI
case.
To be considered available for
additional requirement as fuel
firing & Hydrogen generation
due to this expansion.
No limit on quantity of RLNG
import to be considered.
For the sensitivity case of
captive
power
generation,
RLNG firing to be considered in
CPP.
150 max limit.
Crude Mix for
expansion case
as provided in
the design basis.
Stream hours to
be considered
for all existing 2. Mathura Ref PX
feed Naphtha
and new units=
2.
C7
- C8 from
8000
hours/
PNCP
annum.
4. C9 from PNCP
5. PFO from
PNCP
6. CC4H (LPG)
from PNCP
9. C5 Stream from
PNCP
8. H2 for PNCP
Source
Pipeline
Pipeline
RLNG
Crude Assays
Composition
Database available with EIL used for Methane
Crude Assay.
Ethane
Propane
Isobutane
n-butane
Isopentane
n-pentane
Hexane
Nitrogen
CO2
228
Design :54
Actual : 100
Design :78
Actual : 112
Design : 0
Actual : 200
Design: 0
Actual: 170
Actual : 6.832
Mole %
96.0533
2.8988
0.5675
0.0847
0.1214
0.0014
0.0
0
0.2678
0.0
Products
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 5 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Name
Annual Capacity
Market Place (preferred)
Product names, its maximum and minimum demands and their
specifications are detailed in section 4.1.1 of this document by
client.
Existing Plant Unit details
Process
Units
Capacity
Utilities to be
generated
Capacity
Name
Catalyst / chemicals
Quantity
Unit Rate
Existing unit details are given below in this document by client in section 4.1.6.
Table 4.4 : No. of days of storage
Offsite, raw material/ product and other storages facilities to be provided. Tankage requirement to
be minimized / optimized for integrated Refinery operation at 25.0 MMTPA. Industrial best practices
to be adopted. No of days of storage for raw material, intermediate products and finished products
has been provided by client as follows:
Materials
Raw Material
Crude: 4 Days Inventory + 1 Tank
for M&I at Refinery Site.
Intermediate Products
5 days storage.
Finished Products
7 days storage.
For offsite tank calculation, following philosophy has been adopted by EIL:
 In case the required no. of days (4 for crude, 5 for intermediate products and 7 for finished
products) are not available for base case at 15.0 MMTPA, storage to meet the shortfall shall not
be provided under P-25.
 In case the no. of days (4 for crude, 5 for intermediate products and 7 for finished products) are
surplus for base case at 15.0 MMTPA, margin available shall be considered for new tanks
estimation for P-25.
 For crude storage, separate tanks shall be considered for low sulfur and high sulfur crudes with
4 days of storage for each.
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 6 of 62
No of
No of
State
State
No of days
days of Name
days of Name
Liquid/Solid
Liquid/Solid of Storage
Storage
Storage
The details of existing tankage data is given below in this document by client in section 4.4.
Name
State
Liquid/Solid
Table 4.5 : Hook up connection and Product evacuation
Hook up connection (not applicable for grass root projects)
Name
Distance of connection from existing facilities
Excluded from EIL scope.
PRODUCT EVACUATION BY RAILWAY / TRUCK/ PIPELINE% of product to be
evacuated through
Name
Coastal movement
sea tankers.
Infrastructure cost for additional crude receipt and additional product evacuation: the cost due to this is
not required to be considered under this study.
Product
% of product to
be moved by rail
% of product to
% be evacuated
through Pipeline
% of product to
be
moved by road
Table 4.6 : Utilities
UTILITIES
Raw Water For Plant Operation
Source
From existing system.
Distance from river /sea
By IOCL
Raw water Analysis (if available)
Limitations, if Any
Electric Power For Plant Operation
Source
Volt :
By IOCL
Requirement to augment the existing system will be
jointly reviewed by IOCL & EIL.
Raw water cost as provided by IOCL, Rs. 13.49 per
m3.
Captive/Grid import
Grid Power : 220 KV (Step down to 33 KV)
Captive Power :- 11 to 33 KV (generation level to be
finalized in decision with IOCL)
Distribution :- 33/11/6.6 KV
Utilization : 6.6 KV and 0.4 KV
Frequency
50 Hz
Rate Rs./KWhr
Grid Power : INR 8.45 as provided by IOCL.
Distance :
Available at Refinery B/L
Captive Power to be generated
As required for sensitivity analysis case.
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
UTILITIES
Level of Generation
above
Contract Demand Charges
Refer volt column above
Energy charge
8.45/KWhr as provided by IOCL.
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 7 of 62
INR 170 per KVA per month.
Minimum energy charges (as % of Contract
N/A
demand)
In case this is not available, whether a
system is to be designed /included in
execution.
Construction Power
Available
Yes
Volts
11/6.6/0.4 KV
KM away
Within existing refinery
Rate (Rs./KWhr)
Same as grid power.
Contract Demand Charges
Power available within the plant is being used as
construction power
Energy charges
Minimum energy charges (as % of
Contract Demand)
Construction Water
Available
Yes
KM away
Cooling water
Within existing refinery
The additional requirement of shortlisted expansion case will be worked out by EIL and mutually agreed
hardware configuration for cooling water system will be considered for CAPEX.
Nitrogen system
The additional requirement of shortlisted expansion case will be worked out by EIL and mutually agreed
hardware configuration for Nitrogen system will be considered for CAPEX.
Air system
The additional requirement of shortlisted expansion case will be worked out by EIL and mutually agreed
hardware configuration for Air system will be considered for CAPEX.
Steam system
The additional requirement of shortlisted expansion case will be worked out by EIL and mutually agreed
hardware configuration for steam system will be considered for CAPEX.
DM Water
The additional requirement of shortlisted expansion case will be worked out by EIL and mutually agreed
hardware configuration for DM water system will be considered for CAPEX.
Condensate system
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 8 of 62
UTILITIES
The additional requirement of shortlisted expansion case will be worked out by EIL and mutually agreed
hardware configuration for condensate system will be considered for CAPEX.
Following points in consultation with IOCL has been taken into consideration by EIL for working out the
utilities for the shortlisted case:
1. Post BS-VI at 15.0 MMTPA, no margin is available in existing utility systems- cooling water,
compressed air (PA, IA and nitrogen) etc. Hence, utility requirement of P-25 will be met through
installation of new utility facilities. Nitrogen is not available from existing BOO compressor, hence
nitrogen requirement for P-25 shall be met from new N2 plant.
2. Existing steam generation systems are just adequate post BS-VI at 15.0 MMTPA refinery capacity.
Hence, for steam consumption of new facilities required for expansion from 15.0 MMTPA to 25.0
MMTPA, new steam systems shall be considered.
3. Untreated raw water for P-25 shall be supplied from existing reservoir. However, raw water
treatment and treated raw water reservoir (for 8 hours of storage) shall be considered for P-25.
4. Fire water system/network including fire water reservoir (for 8 hours of storage) shall be considered
for P-25.
5. Post BS-VI at 15.0 MMTPA, no margin is available in existing ETP.
6. Post BS-VI at 15.0 MMTPA, no margin is available in existing Flare system.
7. Post BS-VI at 15.0 MMTPA existing steam generation systems are just adequate. For steam
consumption of new facilities required for expansion from 15.0 MMTPA to 25.0 MMTPA, new steam
systems shall be considered.
Table 4.7: Environmental Requirement
ENVIRONMENTAL REUIREMENT
Effluent Specifications
MoE&F / State Pollution Board
guidelines
MoE&F / State Pollution Board
guidelines
Requirement of secured landfill for
hazardous waste as per guidelines
Liquid Effluent
Gaseous Effluent
Solid Waste
Stack height (Limitation to be specified)
100 m
Location of effluent discharge & its distance from B/L of plant
As per existing refinery standard
Note: Details to be furnished below in case State Pollution Board specifications exist
Green Belt Requirement*
As advised by State Government during site selection visit.
* In absence of this data 100 M all around shall be included.
REIA (in case of DFR) / rapid risk analysis (in case of FR)
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
50 m all around shall be considered.
Rapid risk analysis is excluded
from EIL’s scope of work.
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 9 of 62
Flare
New demountable flare system shall be considered for new facilities at 25.0 MMTPA.
Mitigation / adequacy study is excluded.
ETP
Zero liquid Effluent discharge is to be considered for the expansion case. Accordingly ETP
configuration to be proposed.
Design value of TDS in OWS to existing ETP as provided by IOCL is 1100 mg/l (max).
Table 4.8: Buildings Required
BUILDING REQUIRED (PLANT & NON PLANT)
Name
Type
Shifting to be considered in
discussion with IOCL
As Required. To be
reviewed with IOCL
As Required
Shifting to be considered in
discussion with IOCL
As Required
Administrative Building
Warehouse(Chemical, Spares, Product, Cement)
Workshop
Canteen
Lab
Control room with rooms for operating supervisors
and conference rooms
As required
Shifting to be considered in
discussion with IOCL
As required
Training Center
Substations
Area in M2
As per EIL
As per EIL
As per EIL
As per EIL
As per EIL
Fire station
As required
As per EIL
Operator Cabins
As required
As per EIL
Service Buildings
As required
As per EIL
Security Cabins
As required
As per EIL
Any other building as required
Not Required
-
Table 4.9 : Township
TOWNSHIP :Provision will be made for augmentation of housing only for additional families
% of staff to be provided accommodation
Housing 100%
Hostel 0%
Hospital required
No
No. of Beds --------Market
No
Club with games and sports ground/ complex
No
Swimming pool
No
Housing for Security establishment
No
School up to primary/secondary education
No
Provision of park in township
No
Provision for power, water and sewage disposal
Yes
Township cost of approximately Rs 90 crores has been provided by IOCL.
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
No. of shops --------[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 10 of 62
Table 4.10 : Construction Aids
CONSTRUCTION AIDS
Heavy crane to be purchased by IOCL
No
(If yes, please specify capacity of range proposed and
hiring charges)
Capacity range -----------------Hiring charges ------------------
Whether Hydra, and medium size crane
No
(up to 35 Tons can be brought by Erection Contractor)
Table 4.11 : Owner Expenses during Project Implementation
OWNER EXPENSES DURING PROJECT IMPLEMENTATION
To be Included in report
Expenditure Heads
Expenses towards public issue
As per EIL Standard
Salaries
Perks and facilities to be provided by owner to people
employed on this job
As per EIL Standard
Communication
As per EIL Standard
Travel
As per EIL Standard
Training
As per EIL Standard
legal expenses
As per EIL Standard
PMC fees
As per EIL Standard Norm
Contingency
As per EIL Standard Norm
any other
As per EIL Standard Norm
Total Amount for all the above heads
Rs -------------------------
Table 4.12 : Additional information
ADDITIONAL INFORMATION, FOR MARGIN MONEY CALCULATION
Item
Days
Salaries and wages and operating man-hours /manpower envisaged
As per EIL standard
Repairs and maintenance spare inventory
1 % on Investment
Goods in process
Finished goods
As per EIL standard
As per EIL standard
Bills Receivable (Outstanding)
As per EIL standard
Cash in hand
As per EIL standard
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 11 of 62
ADDITIONAL INFORMATION, FOR MARGIN MONEY CALCULATION
Trade Credits
As per EIL standard
Inventory level for Catalysts
As per EIL standard
Inventory level for Chemicals
As per EIL standard
Table 4.13 : Financial Analysis
INFORMATION FOR FINANCIAL ANALYSIS
Construction Period
36 Months
Project Life
Project Funding
%
25 Years
Grant
0
Equity
50
Debt
50
Expenditure
Equity before debt or concurrent
Pattern
(Grant
Debt/equity Ratio 1:1
Terms Required)
Promoter
Equity
Financial Institution
Contribution %
Public
Equity
Foreign Equity
Composition %
Contributors Equity
Dividend on
Equity
Equity
Promoter fund followed by F1 and then Public
Expenditure
Promoter and F1 equal share and then Public
Pattern
Foreign Equity flow pattern
Debt Composition Foreign Currency
Financial Institutions
%
Suppliers Credit
Financial Institutions
Rupee Portion
Equity before
debt.
N/A for FR
N/A for FR
N/A for FR
N/A for FR
N/A for FR
Debentures to Financial Institutions
Debentures to Public
Terms and
Conditions of
Debts /
Debentures
From FII’s and
Front end processing fees
Suppliers’ Credits
(Foreign Currency Exposure fees
Commitment fees
and Rupee)
Loan Repayment
Terms (Years of
Operation- 10
Yrs)
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
Guarantee fees
Interest Rates and Calculation
Methodology
Moratorium (from Commercial
Operations commencement)
Number of installments
Frequency of Installments
[Type text ]
N/A for FR
2 years
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 12 of 62
INFORMATION FOR FINANCIAL ANALYSIS
Coupon rate
Debentures to Fis
and public
Redemption terms
Interest rate on Short Term Loan
Capacity Build Up 1st Year
N/A for FR
9.35 %
60%
nd
80%
rd
3 Year
100%
4th Year
-
2 Year
th
5 Year
-
Factory Gate Prices for the following to be furnished
Raw Materials & Product prices given in the document to be considered
Applicable Tax Benefits
N/A for FR
Excise Duty
As per prevailing rates
Customs Duty
As per prevailing rates
CST
As per prevailing rates
VAT
As per prevailing rates
Service Tax
As per prevailing rates
Labor Cess on works contract
As per prevailing rates
Corporate Tax rate
34.61
MAT
21.34
NPV Discount Rate
As per prevailing rates
Furnish Crude & Individual Product Price (FOB), freight & Insurance Cost to be considered for
analysis (also provide basis of pricing)
Owner Philosophy for Payment Terms N/A for FR
Project
Period from Zero date to be counted
from (A or B)
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
A
B
Govt. of India Clearance
for financial investment
Availability
of
Process
signing of agreement with
package for Critical Units
process licensor and with
engineering contractor
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 13 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
The tax rates post GST implementation to be considered for P-25 project cost estimation.
1. For Imported items sample calculation is shown below
S. No
Description
RATE
AMT (RS.)
1
Assessable Value( CIF+ Landing Charges)
100.00
2
Basic Customs Duty(BCD)
10%
10.00
3
Customs Education Cess @ 2% on [2]
2%
0.20
4
Customs SHE Cess @ 1% on [ 2]
1%
0.10
5
Safeguard Duty u/s 8B, Antidumping Duty(9a)
/Subsidized(9)
6
Value for IGST [1+2+3+4+5]
7
IGST @ 18% *
8
TOTAL DUTY
0
110.30
18%
19.85
30.15
* CVD & SAD MERGED INTO IGST
2. For indigenous items:
Instead of ED + CST/VAT, GST (CGST+SGST or IGST) to be considered.
GST rate is 18% for majority of capital goods, however same may vary depending on HSN code.
Instead of Service Tax, IGST @ 18% is applicable for majority of the items, however for license
fee & BDEP GST applicable rate is 12%
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 14 of 62
4.1 Basic design parameters for base case
4.1.1 Product Demand & crude portfolio
Product Slate
The product demand considered for this study as provided by client is as below:
Table 4.1.1.1 : Product Slate
Base case for expansion
study (BS – VI Case)
(000 TPA)
Expansion case - to be provided
by IOCL (Min-Max)
(000 TPA)
227
As Produced
0
As produced
RFCC Propylene
120
As Produced
Liquefied Petroleum Gas
649
As produced
Benzene
24.6
Same as Base Case
PTA
700
Product
Off gas (FCC + DCU)
Ethylene
Naphtha for PNC feed
2910 (Phase-I)
Presently 60% sourcing from
Panipat and Balance from
other refineries.
Same as Base Case
Min: Same as Base Case.
Excess Naphtha produced in
expansion case to be routed to
PNCP by reducing Naphtha
Import.
Maximize
Regular Gasoline (BS VI)
1435.2
Premium Gasoline(BS VI)
229.2
As produced
0
Same as Base Case
Aviation Turbine Fuel
1125
2000
Diesel (BS-VI)
7750
Maximize
Bitumen
360
Min. Same as Base Case
High Sulfur Fuel Oil
225
Nil
Pet Coke
874
As produced
Sulphur
652
As produced
LOBS
0
As produced*
LAB
0
As produced
Pitch
0
As produced
Sulfuric Acid
0
As produced
Kerosene
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 15 of 62
*LOBS (Grade-II + Grade-III) maximum capacity to be considered as 500 KTPA. Demand numbers
provided by IOCL are as follows:
2021-22
2026-27
Grade
Gr I
Gr II
Gr III
Total
Gr I
Gr II
Gr III
Total
SN 70 /Gr III 4 cSt
10
130
65
205
10
170
80
260
SN 150/Gr III 6 cSt
38
90
100
228
32
120
125
278
SN 500/ Gr III 8 cSt
80
260
40
380
77
300
50
427
SN 850
13
0
0
13
13
0
0
13
BN/BS 150
40
10
0
50
35
25
0
60
Total
181
490
205
876
167
615
256
1037
Extract
53
60
Grand Total
929
1097
In accordance with demand till 2026-27, LOBS Gr III 4 Cst shall be a maximum of 80 KTPA, LOBS Gr III
6 Cst shall be a maximum of 125 KTPA, and LOBS Gr III 8 Cst shall be a maximum of 50 KTPA. Rest
LOBS Gr II (SN 70, SN 150 and SN 500) may be produced subject to total LOBS Gr III and Gr II production
limited at 500 KTPA.
Subsequently following changes in the product demand slate for the expansion cases were made by IOCL:
 Alkylation unit to be considered for premium gasoline production.
 Maximum demand of ATF in the expansion cases limited to 2000 KTPA.
 Maximum demand of Bitumen to be limited to 500 KTPA.
 Owing to low demand of sulphuric acid a decision is reached not to produce sulphuric acid.
 Ethylene recovery from new units shall not be considered. Ethylene rich fuel gas from new units is
to be considered as fuel to expanded refinery and shall not be considered as export to PNCP for
ethylene recovery.
 Polypropylene production to be considered as 450 KTPA in the expansion cases.
 LOBS production limit increased to 1000 KTPA from 500 KTPA.
 Total MS production to be limited to 3.8 MMTPA.
Table 4.1.1.2: Return Stream from PNCP
Return Stream
C4H (ex PNC)
(000 TPA)
Range (*)
200
0-200
LPG
C7-C8 (ex PNC)
228
228-282
MS Pool
C9 (ex PNC)
100
54-100
MS Pool / DHDT
PFO (ex PNC)
112
78-112
C5 stream (ex PNC)
170
120 - 170
PX feed Naphtha (ex Mathura R efinery)
150
147-153
FO
MS Pool (after treating in
NHDT for 'S' removal & in
Penex for RON boosting)
PX / PTA
Destination
Note: (*) Maximum range to be considered for expansion case, except for C7-C8 stream, for which
minimum value of 228 KTPA is to be considered for expansion case.
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 16 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
4.1.2 Crude Portfolio
Initially the crude mix specified for the study was as follows:
Table 4.1.2.1: Crude Mix for base case and Design Case
Crudes
Base Case
MMTPA
1.0
Expansion Case [MMTPA]
Design
Check
Check
case-1
Case-1 *
case-2 *
0
2.5
0
Assay
(Reference No)
Bonny Lt.
Basrah
Hy.(1)
Kuwait
Refer BS-VI assay
4.0
8.1
7.1
0
Refer BS-VI assay
3.25
12
14.2
13.5
Refer BS-VI assay
Maya
0.75
0
0
5.7
Refer BS-VI assay
Saturno
0
3.7
0
4.6
Assay provided separately
Mangla
1.0
1.2
1.2
1.2
Refer BS-VI assay
Iran mix
1.0
0
0
0
Refer BS-VI assay
Arab mix
1.25
0
0
0
Refer BS-VI assay
Forcados
0.5
0
0
0
Refer BS-VI assay
Escravos
0.5
0
0
0
Refer BS-VI assay
Quaiboe
0.75
0
0
0
Refer BS-VI assay
Zaffiro
0.5
0
0
0
Refer BS-VI assay
Bombay Hi
0.5
0
0
0
Refer BS-VI assay
Notes:
1. In the reference BS-VI study at 15.0 MMTPA, 4.0 MMTPA of blend of Basrah light and Basrah
heavy in ratio of 90:10 wt% is considered. Since it is already agreed with IOCL that crude mix
corresponding to base case shall be same as considered for BS-VI study, 4.0 MMTPA of (Basrah
Lt: Basrah hvy) in (90:10 wt) ratio shall be considered for present study.
Similarly, For Design case 8.1 MMTPA of (Basrah Lt: Basrah hvy) in (90:10 wt) ratio shall be
considered and for check case-1 7.1 MMTPA of 100% Basrah Heavy shall be considered.
2. It is discussed and agreed with IOCL that for the base case of present study, a blend of 15.0
MMTPA crude shall be made and 7.5 MMTPA of this blend shall be routed to CDU-I and 7.5
MMTPA of this blend shall be routed to CDU-II. Similarly for expansion cases, a blend of 25.0
MMTPA crude shall be made and 7.5 MMTPA of this blend shall be routed to CDU-I, 7.5 MMTPA
of this blend shall be routed to CDU-II, and balance 10.0 MMTPA of this blend shall be routed to
new CDU.
Later on during study, design case crude mix was changed to:
Bonny Lt.
Table 4.1.2.2: Crude mix for new design crude mix
Expansion Case [MMTPA]
Crudes
Design
case-1
1.67
Basrah LT: Basrah Hy. (90:10)
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
6.67
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 17 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Kuwait
5.42
Maya
1.25
Saturno
0
Mangla
1.20
Iran mix (75:25)
1.67
Arab mix (50:50)
2.08
Forcados
0.83
Escravos
0.83
Quaiboe
1.25
Zaffiro
0.83
Bombay High
0.83
Dalia
0.47
4.1.3 Feed & Product prices
One year average (2016-17 up to Jan'17) and 3 years average price [2014 (Apr) - 2017 (Jan)] and 5 years
average price [2012 (Apr) - 2017 (Jan)] based on actual Crude price were considered earlier. Similarly,
Product prices were considered based on Refinery Transfer Price (RTP) 1 year average (2016-17 up to
Jan'17) 3 years average price [2014 (Apr) - 2017 (Jan)] and 5 years average price [2012 (Apr) - 2017
(Jan)]. During the course of study the 1 year, 3 year and 5 year average prices (till March, 2017) were
revised. These are reported in tables below:
Table 4.1.3.1 : Feed and Product prices
Streams
1 Year Average
(Rs/MT)
2016-2017(March'17)
3 Years Average
(Rs/MT)
2014-2017
(March'17)
5 years Average
(Rs/MT)
2012-2017 (March'17)
Crude
Mangla
22,529
26,094
32,284
Bonny Light
27,672
32,154
39,105
Basrah Heavy
20,759
25,134
32,372
Basrah Light
23,492
27,388
34,542
Kuwait
23,910
28,218
35,357
Maya
18,908
23,155
31,201
(1)
23,588
28,322
35,187
Arab Mix( 80: 20)
24,442
Arab Mix( 50: 50)
23,726
28,866
28,102
36,172
35,304
Escravos
27,580
32,128
39,224
Forcados
26,879
31,808
38,959
Iran MIX (75:25)
24,511
29,147
36,479
Saturno
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 18 of 62
Quaiboe
28,996
33,062
40,061
Zafiro
Bombay High
25,700
30,401
31,218
37,477
38,043
26,984
Other Feed Streams
C4 LPG
C7 to C8 streams from
PNCP
C-9 Streams from PNCP
(if routed to HSD)
C-9 Streams from PNCP
(if routed to MS)
C-5 Streams from PNCP
Fuel oil
RLNG (Rs/MT)
Methanol (Rs/MT) for
TAME unit
Naphtha from Mathura
refinery to PX-PTA
28472 (same as LPG)
35446
43203
37142 (Same as MS)
43783
51137
31859 (Same as HSD)
37808
45607
37142 (Same as MS)
43783
51137
37142 (Same as MS)
36,528 (Same as
HSFO)
31017
43783
51137
-
-
-
13,860
-
25,166
31,369
38,331
Naphtha Ex. Mathura
Transport cost + Add: Non
Cenvatable (Rs./MT)
720
Min- Max limit
KT/month
35 - 40
Naphtha Ex. Gujarat
2656
20 - 45
Naphtha Ex. Barauni
2844
25 - 40
Naphtha Ex. Bongaigaon
3818
10 - 10
Naphtha Ex. Haldia
3561
10 - 12
Streams (3)
1 Year Average
(Rs/MT)
20162017(March'17)
3 Years Average
(Rs/MT)
2014-2017 (March'17)
5 years Average
(Rs/MT)
2012-2017 (March'17)
Fuel gas(2)
19,026
22,959
28,680
LPG
Ethylene
28,472
34,937
35,446
42,375
43,203
50,722
Propylene (Mathura)
39,170
46,608
54,955
MS BS VI Regular
MS BS VI Premium
37,142
38,935
43,783
45,507
51,137
52,786
SKO
32,417
39,378
47,056
Streams
Products
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 19 of 62
1 Year Average
(Rs/MT)
20162017(March'17)
3 Years Average
(Rs/MT)
2014-2017 (March'17)
5 years Average
(Rs/MT)
2012-2017 (March'17)
ATF
31,731
38,712
46,479
HSD BS VI
31,859
37,808
45,607
HSFO
19,844
23,946
29,913
Bitumen VG30
20,217
25,986
29,582
Sulphur
5,354
7,418
7,300
Coke
PNCP Naphtha (EPP)
5,233
25,166
5,115
31,369
5,542
38,331
PTA
40,179
42,145
49,626
Group II - H-70
32,701
39,435
47,142
Group II - H-150
35,561
43,943
50,473
Group II - H-500
44,858
48,771
55,116
Group III - 3 cst
34,701
41,435
49,142
Group III - 4 cst
36,319
43,877
50,996
Group III - 6 cst
37,937
46,319
52,849
Group III - 8 cst
LAB
46,858
34,644
50,771
85828
57,116
49,151
MEG
46,059
47,400
50,915
PET
59,688
63,231
70,079
Benzene
47,524
51,638
58,889
Streams
Products
Lubes
H2SO4
4,000
Note: (1) Dalia Crude price has been considered for Saturno crude.
(2)
227 KTPA of RFCC and DCU offgas in the base case shall be sent to PNCP at fuel gas price.
After ethylene recovery in PNCP, balance fuel gas shall be received by refinery at the same price.
During the course of study, IOCL decided that a common facility for ethylene recovery will be
provided in the refinery complex, hence offgas from RFCCU and DCU shall be sent to PNCP at fuel
gas price and ethylene recovery will not be considered in this study.
(3)
For expansion cases, naphtha from refinery to PNCP shall be minimum 60% (1746 KTPA) and
maximum 100% (2910 KTPA) of the total naphtha requirement in PNCP (2910 KTPA). Later on, the
minimum quantity of naphtha from Panipat refinery to PNCP was revised as 2200 KTPA by IOCL.
Incase 100% naphtha requirement is not met from Panipat refinery, then PNCP shall import naphtha
from other refineries in the following order:

Naphtha Ex. Mathura (0-480 KTPA)
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 20 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL







Naphtha Ex. Gujarat (0-540 KTPA)
Naphtha Ex. Barauni (0-480 KTPA)
Naphtha Ex. Bongaigaon (0-120 KTPA)
Naphtha Ex. Haldia (0-144 KTPA)
Naphtha which is sent to PNCP in expansion cases shall be evaluated at the following prices:
0-2200 KTPA @ (3 year avg price Naphtha Export parity price)
2200 KTPA - 2680 KTPA (2200+480) @ (3 year avg price Naphtha Export parity price + Rs. 720/
MT; transportation cost from Mathura refinery)
2680 KTPA - 2910 KTPA (2680+540) @ (3 year avg price Naphtha Export parity price + Rs. 2656/
MT; transportation cost from Gujarat refinery)
4.1.4 Other feed stream specifications from PNCP
Specifications of the feed streams coming from PNCP as provided by client:
Table 4.1.4.1: Feed stream specifications from PNCP
C5
Parameters
Sp gravity
C9
C7- C8
PFO (PNCP)
0.916
1.054
RON
103
0.845
0.1 - 0.2 wt ppm
Max
100
MON
94
94
-
80 wt %
75 wt%
-
2 ppb
0.054 to 0.9 Vol %
-
20 wt %
0 - 60 wt ppm Max
-
-
-
9.69 @ 90 oC
-
-
(-) 09
-
-
72
Sulphur ppm
150 - 250
0
Aromatics
Benzene
Olefins
Viscosity (CST @ 50
o
C)
Pour point oC
0.026 vol%
o
Flash pt C
400
-
4.1.5 Product Specifications
Following Table shows the product specifications adopted for expansion Project:
Table 4.1.5.1 : Product Specifications
PRODUCT
UNIT
SPECIFICATION
LPG
Vapor pressure at 40 °C, max
(BIS:4576-1999)
kPa
1050
Odor, min
Unpleasant and distinctive down to 20% LEL
Dienes (as 1,3 Butadiene)
mole%
0.5
C5 plus, max
mole%
2
Total volatile sulphur, max
wppm
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
150
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 21 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Copper strip corrosion, max
No. 1
Hydrogen sulphide
wppm
Pass the test
Mercaptans
wppm
Nil
Free water
Nil
Evaporation residue, mg/kg, max
100
Export grade Naphtha
Specific gravity (min/max)
(0.65/0.74)
o
RVP (100 F), max
Sulphur, max
Psia
10
Wppm
500
PNCP Naphtha (Present Blend of the naphtha streams will be maintained)
Specific gravity (min/max)
(0.65/0.74)
RVP (100 Deg F), max
Psia
10
Wppm
500
Recovery at 180 C
Vol %
100%
Olefins max
Vol%
1%
Sulphur, max
o
BS-VI MS Regular
S. No.
Parameters
1
Density @ 15 oC
2
Distillation
BS -VI
Spec
720 – 775
Unit
Kg/m3
Panipat
720 - 773.7
E-70
% Vol
E-100
% Vol
10-55(summer)
10-58(other month)
40-70
E-150
% Vol
75 min
75
FBP
o
210
200
Residue
% Vol. Max
2
2
3
Sulphur, Total
mg/kg max
10
8
4
RON
Min.
91
91.5
5
MON
Min.
81
81.4
6
RVP @ 38 oC
kpa
67
60
Summer (May to Jul)
Max
1050
750
Others
Max
1100
950
8
Benzene
% Vol-max
1
1
9
Aromatics
% Vol-max
35
35
10
Olefin
% Vol-max
21
21
C max
11 - 45
40 - 70
VLI (10RVP+7E70)
7
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 22 of 62
BS-VI MS Regular
S. No.
Parameters
BS -VI
Spec
-
Unit
11
Existent Gum
g/m3-max
12
Gum(Solvent washed)
mg/100 ml max
13
Oxidation Stability
Minutes-Min
14
Lead as Pb
g/l-max
15
Oxygen content ,max
%wt-max
BS-VI MS Premium
Sl.
Parameters
No.
1
Density @ 15 oC
Unit
Kg/m3
Panipat
-
4
5
360
360
0.005
0.005
3.7
2.7
BS -VI
Spec
720-775
Panipat
720 -773.7
Distillation
E-70
% Vol
E-100
% Vol
10-55(summer),
10-58(other months)
40 – 70
% Vol
75 min
75
C max
210
200
Residue
% Vol. Max
2
2
3
Sulphur, Total
mg/kg max
10
8
4
RON
Min.
95
95.5
5
MON
Min.
85
81.4
kpa
67
60
Summer (May to Jul)
Max
1050
750
Others
Max
1100
950
2
E-150
o
FBP
o
6
RVP @ 38 C
7
VLI (10RVP+7E70)
11-45
40-70
8
Benzene
% Vol-max
1
1
9
Aromatics
% Vol-max
35
35
10
Olefin
% Vol-max
18
18
11
Existent Gum
g/m3-max
mg/100 ml
max
Minutes-Min
4
5
360
360
g/l-max
0.005
0.005
%wt-max
4.5
2.7
12
13
Gum(Solvent washed)
Oxidation Stability
14
Lead as Pb
15
Oxygen
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 23 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Kerosene
Specific gravity (min/max)
0.775/0.84
Aromatics, max
vol%
report
Olefins, max
vol%
5
Sulfur total, max
wt%
0.25
10 % recovery ,(ASTM D86) max
FBP, (ASTM D86) max
o
Flash point (Abel),min
o
C
C
205
280
o
Smoke point
C
38
mm
18
Aviation Turbine Fuel
Specific gravity (min/max)
0.775/0.84
Aromatics, max
vol%
22
Olefins, max
vol%
5
Sulfur total, max
wt%
0.25
10 % recovery ,(ASTM D86) max
FBP, (ASTM D86) max
o
205
280
Freeze Point, max
o
C
C
o
Smoke point
C
(-) 47
mm
20
BS-VI Diesel
S No
1.
Parameters
Density at 15 oC
Unit
BS VI Spec
Panipat Spec
Kg/m3
845
845
C max
360
360
Mg/Kg, max
10
8
o
2.
Distillation T-95
3.
Sulfur, Total
4.
Cetane Number, min
-
51
51.4
5.
Cetane Index, min
-
46
46
6.
Flash Point
C
35
42
Cst
2.0 - 4.5
2.15 - 4.5
o
o
7.
Kinematic Viscosity at 40 C
8.
PAH, max
Wt %
8
11
9.
Total Contaminants, max
Mg/kg
24
24
21 / 18
Mg/kg
25
0.3 (without
additive)
200
microns
460
420
Wt %
0.01
0.01
10.
12.
Oxidation stability, max
Carbon Residue (Ramsbottom) on
10 % residue, max
Water Content, max
13.
Lubricity Corrected WSD, max
14.
Ash, max
11.
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
gm/m
3
Wt %
[Type text ]
0.3
200
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 24 of 62
High Sulphur Fuel Oil
Sulphur, max
% wt
4
Sediments, max
% wt
0.2
°C
66
Kinematic Viscosity @ 50 C, max
cSt
175
Pour point
°C
15 winter, 21 summer
Flash Point(PMCC), min
o
Notes:
1. Fuel oil & Fuel gas LHV shall be considered as 9700kcal/kg and 9300 kcal/kg respectively. For natural
gas calorific value shall be in line with the composition provided above.
2. IFO burning shall be considered for the expansion case based on economics. SOx limit of 1000
kg/hr is for refinery alone. SOx limit is 275 kg/hr for PX-PTA alone.
4.1.6 Existing units
Existing units are briefly described below:
Table 4.1.6.1: Table for Existing Units
PANIPAT REFINERY – LIST OF PROCESS UNITS
PANIPAT REFINERY (PR) UNITS
S.NO.
UNIT NAME
UNIT NO.
CAPACITY
LICENSOR
1.
2.
CDU, VDU
NSU-1 REVAMP
3
1.312 MMTPA
TECHNIP KTIL
3.
OHCU (Note-1)
5
1.9 MMTPA
UOP, IOCL
4.
HGU
6
38 KTPA
HALDAR TOPSOE
5.
RFCCU
7
0.85 MMTPA
SWEC,IOCL,EIL
6.
PSU
33
0.255 MMTPA
EIL
7.
CRU
8
IFP - AXENS
8.
DHDS
52
9.
VBU
9
0.64 MMTPA
0.55 MMTPA
(Based on BS VI FR)
0.4 MMTPA
10.
BBU
ATF MEROX (Converted
from Gasoline Merox)
LPG MEROX
10
0.5 MMTPA
EIL
12
30 m3/hr
UOP, IOCL, EIL
13
50 m3/hr
UOP, IOCL, EIL
15
180 m3/hr
22/44
115 TPD
15.
ATF-KERO MEROX
SRU/SSRU ( Common
Incinerator)
ARU
21
400 m3/hr
UOP
DELTA HUDSON
- EIL
EIL
16.
SWS-I (REFINERY)
71.8 m3/hr
EIL
11.
12.
13.
14.
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
03, 04, 19
17
[Type text ]
7.5 MMTPA
EIL,IOCL
IFP - AXENS
EIL
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
SWS-II
18
(HYDROPROCESSING)
PANIPAT REFINERY EXPANSION (PRE) UNITS
16.4 m3/hr
17.
S No
UNIT NAME
1.
CDU, VDU
2.
NSU-2
3.
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 25 of 62
EIL
UNIT NO.
CAPACITY
73, 74
7.5 MMTPA
EIL
59
0.72 MMTPA
TECHNIP KTIL
HGU
76, 77
2 X 70 KTPA
HALDER TOPSOE
4.
HCU
75
1.9 MMTPA
UOP
5.
DCU
78
3.0 MMTPA
ABB LUMMUS
6.
7.
COKER LPG MEROX
DHDT
79
72
0.1 MMTPA
3.5 MMTPA
UOP
AXENS
8.
SRU-I
55
225 TPD
BLACK & VEATCH
9.
SRU-II
56
225 TPD
BLACK & VEATCH
10.
TGU
BLACK & VEATCH
11.
ARU
EQ.450 TPD
SULPHUR
410 m3/HR
12.
13.
57
51
SWS-I (REFINERY)
53
3
170 m /HR
3
SWS-II (HYDROPROCESSING)
40 m /HR
54
PARA XYLENE AND PURIFIED TEREPHTHALIC ACID (PX and PTA) UNITS
S.NO.
UNIT NAME
1.
NHT, CCR
2.
SHELL SULFOLANE
3.
PAREX
4.
UNIT NO.
201,
202, 203
204
CAPACITY
MMTPA
LICENSOR
BLACK & VEATCH
EIL
EIL
LICENSOR
0.628
UOP
0.115
UOP
205
2.494
UOP
XFU
206
0.693
UOP
5.
ISOMAR
207
2.203
UOP
6.
TATORAY
208
0.624
UOP
7.
BTF
209
0.615
UOP
8.
PTA
221
DUPONT
9.
ERU
-
0.7
0.227 MMTPA
(Feed)
Thyssen Krupp
MS QUALITY UPGRADATION (MSQ) UNITS
S.NO.
1.
NHT /PENEX
301
2.
RSU
FCC GDU
C9 stream PNCP shall be routed
to second stage HDS of Prime G
unit. (100 KTPA).
302
CAPACITY
410 / 400
TMTPA
470 TMTPA
303
445 TMTPA
3.
UNIT NAME
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
UNIT NO.
[Type text ]
LICENSOR
UOP
IFP - AXENS
AXENS
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 26 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT (PRAEP) UNITS
S.NO.
UNIT NAME
UNIT NO.
CAPACITY
LICENSOR
1.
SWS
20
40 m3/HR
EIL
2.
SRU-III
25
BLACK & VEATCH
3.
TGU
26
225 TPD
EQ.450 TPD
SULPHUR
UNIT NO.
CAPACITY
LICENSOR
BLACK & VEATCH
BS-VI UNITS
S.NO.
UNIT NAME
1.
DHDT
-
2.2 MMTPA
UOP
2.
HGU
-
44 KTPA
-
3.
SRU
-
225 TPD
Prosernet
4.
TAME
-
36 KTPA
-
5.
ARU
-
6.
SWS (Hydroprocessing)
-
7.
Octamax
-
3
189 m /hr
56.7 m3/hr
Not to be
considered in base
case
EIL
EIL
IOCL R&D
Notes:
1. In expansion cases, revamp of OHCU shall be considered from 1.9 MMTPA to 2.4 MMTPA at a cost of
552 Crores.
2. In order to establish new HGU capacity, existing HGU’s operating capacities to be considered as 90%
of respective design capacities as follows:
Design capacity
PR HGU
PREP HGU
BS-VI HGU
38 KTPA
140 KTPA
44 KTPA
Operating capacity to be
considered for new HGU
capacity calculation
34.2 KTPA
126 KTPA
39.6 KTPA
3. In order to establish new SRU capacity, existing SRU’s capacities to be considered as follows:
Design capacity
PR SRU
PREP SRU
115 TPD
225*3 TPD
BS-VI SRU
225 TPD
Operating capacity to be
considered for new SRU
capacity calculation
115 TPD
225*2 TPD (considering 1
train spare)
225 TPD
4. Post BS-VI at 15.0 MMTPA, no margin is available in existing SWS-I, SWS-II and ARU units.
5. Post BS-VI at 15.0 MMTPA, no margin is available in existing SR fuel gas and SR LPG treating units.
6. Post BS-VI at 15.0 MMTPA, no margin is available in existing SR fuel gas and SR LPG treating units.
Unit wise yield, disposition of streams, quality & utility consumption are provided in the next section.
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 27 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
A. AVU-I
CDU-I
CAPACITY(MMTPA)
7.5
LICENSOR
EIL, IOCL
HS (KUW, BASRA LT, AM, IM),
LS(BONNY LT, BH)
8000
FEED
On-stream Hours
Cut points & stream disposition
AVU-I LS
Stream
IBP
FBP
Routings
MSQ
28
85
MSQ, PNC Naphtha
S/C
85
113
PNC Naphtha
CRU Swing
113
122
CRU, PNC Naptha
CRU
122
142
CRU, PNC Naptha
HN Swing
142
149
CRU, PNC Naptha
HN
149
165
HSD-IV, PNC Naptha
SKO
165
240
SKO, ATF Merox, DHDT
SKO Swing
240
251
SKO, DHDT
LGO
251
300
DHDS/DHDT
HGO
300
335
DHDT
Vac Diesel
335
362
DHDT
LVGO
362
410
HCU/OHCU/RFCCU
HVGO
410
502
HCU/OHCU/RFCCU
VS Swing
502
510
HCU/OHCU/RFCCU/DCU/IFO
VS
510
525
DCU/IFO/RFCCU
VR
525
9999
DCU/IFO/RFCCU
Stream
IBP
FBP
Routings
MSQ
28
95
MSQ, PNC Naphtha
S/C
95
113
PNC Naphtha
CRU Swing
113
122
CRU, PNC Naphtha
AVU-I HS
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 28 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
CRU
122
142
CRU, PNC Naphtha
HN Swing
142
149
CRU, PNC Naphtha
HN
149
165
HSD-IV, PNC Naphtha
SKO
165
240
SKO, ATF Merox, DHDT
SKO Swing
240
255
SKO, DHDT
LGO
255
315
DHDS/DHDT
HGO
315
360
DHDT
Vac Diesel
360
370
DHDT
LVGO
370
435
HCU/OHCU/RFCCU
HVGO
435
545
HCU/OHCU/RFCCU
VS Swing
545
555
HCU/OHCU/RFCCU/DCU/IFO
VS
555
565
DCU/IFO/RFCCU
VR
565
9999
DCU/IFO/RFCCU
Utilities for AVU-I









Cooling water (m3/t of feed): 7.25
Power( KWh/Mt): 11.77
STEAM : MP = 67 Kg/Mt ,MLP steam=8.5 Kg/MT , LP steam = 16.5 Kg/MT
Fuel gas/ Fuel Oil (Gcal/MT) : 0.144
Nitrogen:
Instrument Air
Plant Air
DM Water
Condensate:
B. AVU-II
CDU-II
CAPACITY(MMTPA)
7.5
LICENSOR
EIL, IOCL
FEED
HS (KUW, BASRA LT, AM, IM, MAYA & MANGLA)
On-stream Hours
8000
AVU-II HS
Stream
IBP
FBP
MSQ
28
85
PNC Naphtha / MSQ
SRN
85
115
PNC Naphtha
PX
115
138
PX/CRU Feed, PNC Naphtha
PX
138
145
PX/CRU Feed, PNC Naphtha
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
Routings
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 29 of 62
AVU-II HS
Stream
IBP
FBP
Routings
HN
145
155
PX/CRU Feed, PNC Naphtha
HN
155
165
HSD-IV, Naphtha
SKO
165
240
SKO, DHDT Feed
SKO Swing
240
255
SKO, DHDT feed
LGO
255
300
DHDS/DHDT
HGO
300
355
DHDT
Vac Diesel
355
380
DHDT
LVGO
380
460
HCU/OHCU/RFCCU
HVGO
460
550
HCU/OHCU/RFCCU
VS
550
560
DCU/ RFCCU
VR
560
9999
DCU/ RFCCU
Utilities for CDU-II









Cooling water (m3/t of feed): 6.03
Power( KWh/Mt): 8.55
STEAM : MP = 32.1 Kg/Mt ,MLP steam=18.2 Kg/MT , LP steam = 9.9 Kg/MT
Fuel gas/ Fuel Oil (Gcal/MT):0.109
Nitrogen:
Instrument Air
Plant Air
DM Water
Condensate:
Notes:
1. Low Sulfur Crudes processing preferentially in AVU-1 and AVU-2.
2. High TAN crudes processing preferentially in AVU-2 and new Crude unit.
C. NAPHTHA HYDROTREATER
NHT
CAPACITY(MMTPA)
0.64
LICENSOR
Axens
HV Naphtha from CDU-I, CDU-II & Heavy Naphtha from
OHCU
8000
FEED
On-stream Hours
NHT Feed Quality
Feed Sulfur in ppm:
700 max
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 30 of 62
NHT yield pattern
COMPONENTS
Feed
Design wt%
Actual wt %
100.00
100.00
0.11
0.12
Total
100.11
100.12
H2S
-
0.03
Fuel Gas
0.14
0.29
CCR Feed
99.97
99.80
Total
100.11
100.12
H2 Make-up
Utilities (combined utilities for CCR &NHDT)








Power( KWh/Mt): 10.11
Steam: HP Steam= 377.7 kg/MT, MP steam gen= 15 Kg/ Mt ;MLP Steam= 377.7
Cooling Water ( M3/MT of Feed): 32
Condensate (tons/hr): 3.2
Fuel (Gcal/MT): 0.01
Nitrogen:
Instrument Air
Plant Air
 DM Water
D. CCR
CCR yield pattern
COMPONENTS
Design wt%
Actual wt%
DESTINATION
RON 98
RON 96
Feed
100.00
100.00
Total
100.00
100.00
Fuel Gas
0.47
0.12
FG header
LPG
1.39
3.78
AVU-I stabilizer
H2 Rich Gas
5.11
5.09
HGU-I PSA + impure H2 header
Reformate
93.04
91.00
To be split in RSU for Lt and heavy
Lt. Reformate
4.65
4.55
ISOM
Hy. Reformate
88.39
86.45
MS Pool
Total
100.00
100.00
Reformate Quality
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 31 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Parameter
Actual
HV RFT
Actual
675
675
839
839
<1 ppm
<1 ppm
<1 ppm
<1 ppm
Aromatics vol%
13.5
13.5
71
68
Benzene vol%
12.5
12.5
0.5
1.0
11.9
11.9
Density@15°C, kg/ m
LT RFT
3
Distillation IBP°C / FBP°C
Sulphur
Naphthenes vol %
Olefin vol%
2
2
0.1
0.1
MON
73
73
90
90
79
79
102.4
97
0.1
0.1
RON
RVP kg/cm
2
Reformate Quality
Parameter
Design: Un splitted Reformate
Actual
804.8
814.2
3
Density@15°C, kg/ m
Distillation IBP°C / FBP°C
65 - 200
Sulphur
0.1
Aromatics vol%
68.68
70.04
Benzene vol%
0.44 wt%
1.6
0.46
2.06
Naphthenes vol %
Olefin vol%
1.15
MON
88
RON
RVP kg/cm
2
98
95.5
0.3
0.1
Utilities (combined utilities for CCR &NHDT)








Power( KWH/Mt): 58.6
Steam : MP steam cons = 127 Kg/ Mt
Nitrogen ( Nm3/Hr):
Cooling Water ( m3/MT of Feed) : 32
Condensate gen (tons/hr) : 22.24
Demin water (tons/hr): 4.8
Fuel (Gcal/MT) : 0.587
Instrument Air:
 Plant Air:
E. RESID FLUID CATALYTIC CRACKING UNIT
RFCCU
CAPACITY(MMT PA)
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
0.85
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 32 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
LICENSOR
SWEC,IOCL,EIL
‘OHCU & HCU’ Bottom, VGO, Vac Slop from CDU-I& II, Vac
Residue from CDU-I & CDU-II
FEED
On-stream Hours
8000
CCR in RFCC to be maintained between 1 wt % to 1.5 wt %.
Yield pattern
COMPONENTS
Design WT%
Actual wt
%
DESTINATION
2.9
Amine treatment and routing to Ethylene
Recovery Unit in PNCP.
H2S
0.16
RFCC Gas
3.4
PROPYLENE
8.1
6.21
LPG Pool
PROPANE
21.1
2.25
LPG Pool
14.7
C4 LPG
GASOLINE C5- 120 oC
37.4
38.1
MSQ GDS Unit
DIESEL 120-380 C
23.1
21.6
DHDT/DHDS
DECANT OIL 380+
1.5
9.4
DCU
COKE/LOSS
5.5
4.7
100.0
100
o
TOTAL
Stream properties
SI.
No.
1
Parameters
Density @ 15 oC
RFCCU
Feed
0.8821
LCN
LCO
CLO
0.7062
0.880
1.088
Distillation
2
IBP
332
36
95
258
5%
381
42
153
322
10%
402
45
170
339
50%
442
73
218
398
90%
514
152
261
493
95%
530
164
268
528
FBP
551
180
283
562
3
RON
4
BS&W
5
Cetane No.
6
RCR7 CCR, wt%
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
90
0.8
29
1.44
5.6
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 33 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
SI.
No.
7
8
Parameters
Sulphur. wt%
RFCCU
Feed
1.04
LCN
280ppm
2
9
RVP, Kg/cm
Metal (Ni)
10
Metal (V)
7.8
11
Benzene %vol
0.3
12
Paraffins% V
13
Olefins% V
14
Naphthenes% V
15
Aromatics% V
LCO
0.91
CLO
3.48
0.54
1.8
39
12
Further, for the consideration of an alkylation unit composition of RFCC LPG was provided by client as
follows:
Major Component
Design %W
Ethane
0.2
Propylene
29.8
Propane
11.2
Isobutane
24.9
Butane
6.9
1 Butene
6.3
I Butene
8.8
T2 Butene
6.4
C2 Butene
1,3 Butadiene
N+ Iso Pentane
H2S
4.7
0.1
0.6
0.1
Total
100.0
Utilities (per MT of feed)









Cooling water ( M3/t of feed):
Power( KW/Mt):
Net LP steam consumption:
Net MP steam consumption:
HP Steam generation(KG/T):
Fuel gas/ Fuel Oil ( KG/MT):
DM Water ( KG/T):
Condensate (KG/T):
Nitrogen(kg/T):
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
20.24
35.84
61.20 kg/Mt
78.41 Kg/MT
475.95 kg/Mt
15.38
509.80
377.92
0.28
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
 Plant Air(Kg/T):
 Instrument Air
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 34 of 62
13.35
F. HGU
HGU-I
CAPACITY (KTPA)
38
LICENSOR
HALDOR TOPSOE
FEED
Neat RLNG, Neat Naphtha or mix RLNG-Naphtha
On-stream Hours
8000
S.No
PROPERTY
ARAB MIX NAPHTHA (C-5-90
cut)
BOMBAY HIGH NAPHTHA (C-5-90
cut)
Total sulphur,
160-200
2-5
ppmw
Naphthenes
2
11-20
25-35
(vol%)
Plant's design case is 100% ARAB mix Naphtha.
Note :
 The plant is designed to process 100% RLNG, and 50% RLNG+50% Naphtha cases
 Unit is designed for only above Naphtha as feed and make up fuel.
HGU can process coker naphtha/ SR naphtha/ RLNG in any proportion, provided sulfur in feed is
maintained within 200 wppm.
1
Yield pattern
COMPONENTS
Design
WT %
Actual wt% RLNG
Actual wt% Naphtha
OFF GAS
68
64.1
67.57
H2
32
35.9
32.43
TOTAL
100
100
DESTINATION
Gets consumed as
fuel in HGU internal.
Utilities









Power ( KWH/MT) : 71.2
Steam: HP steam gen= 3090 Kg/Mt, MP steam con: 86 KG/MT LP steam con: 287 KG/MT.
Condensate GEN ( TPH)
DM Water ( m3/Hr): (normal); ( peak)
Cooling Water (m3/ MT of Feed) : 27.8
Nitrogen:
Instrument Air
Plant Air
DM Water
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 35 of 62
G. ONCE THROUGH HYDROCRACKER
OHCU
CAPACITY(MMTPA)
1.9
LICENSOR
UOP, IOCL
FEED
VGO from CDU-I &II, Heavy Coker Gasoil from DCU
Slop from VDUs shall not be routed to because of limitation on
arsenic and other metals in feed
8000
On-stream Hours
OHCU revamp with 4 drum system shall be considered for the expansion cases with the revamped
capacity of 2.4 MMTPA.
OHCU Feed Specifications
Property
Value
CCR, wt%
0.59 max
Cracked feed to OHCU (to maintain nitrogen within limit) is maintained within 20 wt% of total feed as per
discussion with client.
OHCU Yield pattern
Yield pattern
Feed
Design Wt%
Actual wt%
Disposition of stream
100
100
2.425
2.249
102.425
102.249
H2S
3.29
2.24
FGAS
0. 26
0.17
LPG
2.46
0.72
HC LIGHT NAPHTHA
6.295
2.97
HCU HV. NAPHTHA
1.81
9.31
HC KEROSENE
18.92
19.54
HC DIESEL
39.395
37.83
HSD Pool
BOTTOM
30.00
29.48
RFCC Feed
Total
102.43
102.249
Hydrogen
Total
From HGU
Products
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
ARU/SRU
Fuel Gas system
LPG pool
LNHT/ MS Pool
Aromatic Complex thru
NSU 2
OHCU heavy naphtha may
also be routed to CCR
ATF,HSD pool
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 36 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
OHCU Stream Properties
LT Naph
Hy. Naph
Kero
Diesel
Bottom
Des.
Act
Des.
Act
Des.
Act
Des.
Act
Specific Gravity
0.71
5
0.66
0.77
6
0.75
0.79
2
0.81
0.83
7
0.84
Distillation
D-86
IBP
32
5
D-86
36
125
43
10
57
30
77
50
92
70
100
90
112
95
161
100
251
163
436
436
465
465
507
507
594
594
Pour Pt °C
25
25
CCR wt%
0.1
0.1
<20
<20
21.9
21.9
4.6
4.6
Sulphur, ppm
52
126
129
73
<1
172
108
129
68
96
<1
120
196
<1
145
189
290
221
343
229
206
273
296
318
245
346
347
355
<1
<5
<5
<15
28
<55
45
>60
Freeze Pt °C
Flash Pt °C
Cetane Index (D
4737)
Cetane
Number(D 613)
Viscosity
@38°C/@ 40°C
cSt
Viscosity
@50°C cSt
Viscosity
@100°C cSt
257
271
188
Smoke Pt mm
RON Clear
182
124
131
166
269
413
125
165
256
413
125
102
155
0.84
0.86
2
DD- 1160
1160
360
360
398
FBP
125
D-86
Act
398
95
46
D-86
Des.
60
27
58
11.5
73
73
75
70
70
0.09
max
MON
71
71
74
Aromatics (wt
%)
27
3
7
RVP
Kpa
@ 38C
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 37 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
LT Naph
Des.
Paraffins (wt %)
Naphthenes (wt
%)
Benzene (Vol
%)
Olefins (vol %)
Hy. Naph
Act
Des.
72
89
2
3
0
0.2
0
0
Kero
Act
Des.
Diesel
Act
Des.
Act
Bottom
Des.
Act
Utilities









Cooling water (m3/t of feed): 15.14
Power( KWH/Mt): 58.08
Steam : HP steam con=101.7 Kg/Mt; Net MLP Generation =1.07 Kg/ Mt; Net MP Steam con
=19.3 kg/MT ; Net LP Con=21.5 Kg/ Mt ;
Fuel gas/ Fuel Oil (Gcal/MT) : 0.224
DM Wat er (m3/hr) : 14.36
Condensate (TPH) : 29 (average)
Nitrogen:
Instrument Air
Plant Air
H. ATF/KERO MEROX
ATF/KERO MEROX
CAPACITY(TMTPA)
1.34
LICENSOR
UOP
FEED
Kerosene from CDU-I & II
On-stream Hours
8000
Utilities








I.
MP Steam consumption : N/A
Power: N/A
Condensate: N/A
Nitrogen: N/A
Instrument Air: N/A
Plant Air: N/A
DM Water: N/A
Condensate: N/A
ATF MEROX (Converted from Gasoline Merox)
ATF MEROX
CAPACITY(TMTPA)
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
0.19
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
LICENSOR
UOP
FEED
Kerosene from CDU-I & II
On-stream Hours
8000
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 38 of 62
Utilities of ATF Merox







MP Steam consumption : N/A
Power: N/A
Condensate: N/A
Nitrogen: N/A
Instrument Air: N/A
Plant Air: N/A
DM Water: N/A
 Condensate: N/A
J. LT NAPHTHA HYDROTREATER
NHT
CAPACITY(MMTPA)
0.41
LICENSOR
UOP
FEED
C5-90 SRN from AVU-I and AVU-II NSU
On-stream Hours
8000
LT NHT Yield pattern
COMPONENTS
Design: wt % (N/A)
Actual wt%
FEED
99.9
H2
0.1
TOTAL
100
PRODUCT
H2S
0.1
FUELGAS
1.65
Hydrotreated Naphtha to ISOM.
98.35
Total
100
Utilities






Power( KWH/Mt): 11.44
Steam : HP steam cons = 190 Kg/ Mt, MP steam con= 130 Kg/ Mt,
Condensate gen ( TPH) : 23.1
Fuel (Gcal/MT):0.039
Nitrogen:
Instrument Air
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 39 of 62
 Plant Air
 DM Water
K. ISOM
ISOM
CAPACITY(MMTPA)
0.4
LICENSOR
UOP
FEED
ISOM Feed from Lt NHT & Lt Reformate from CCR
On-stream Hours
8000
Yield pattern
COMPONENTS
Design: WT%
Actual wt%
Feed
100
99.3
High Purity H2
1.6
0.7
101.64
100
ISOM.FUEL GAS
1.05
2.5
FG
ISOMER.LPG
6.6
0
NA
Isomerate
93.1
97.5
MS pool
101.6
100
Total
Total
DESTINATION
Stream property
STREAM PROPERTIES
Sp Gravity
DESIGN : ISOMERATE
ACTUAL
Not available
0.6603
o
Distillation IBP C
0% Rec @ oC
10% Rec @ oC
70% Rec @ oC
100% Rec @ oC
FBP
N2 ppm
Not available
70 OC – 47 %V
100 OC- 95 %v
102
Not available
Not available
Benzene max %
0.1 max
0.1 max
RON
87 min
87
MON
84 min
Sulfur
0.3 ppm wt max
0.3 ppm wt max
85.5/105
1 kg/cm2 A
Not available
Not available
0
0
Not available
Not available
RVP KPa
Naphthenes vol%
Aromatics Vol%
Paraffins vol%
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 40 of 62
Olefin Vol%
0.1 max
0.1 max
Benzene vol%
0.1 max
0.1 max
Not available
Not available
Concarbon
RON and RVP of isomerate stream changed to 87 and 1 kg/cm2a in consultation with client.
Utilities







Power( KWH/Mt): 20.57
Steam : HP steam cons = 299 Kg/ Mt, MP steam con= 49 Kg/ Mt, LP steam gen= 93 Kg/ Mt
Condensate gen ( TPH): 24.2
DM water (m3/hr):
Fuel Gas / Fuel Oil ( % SRF) :
Nitrogen:
Instrument Air
 Plant Air
L. PRIME G
PRIME G
CAPACITY(MMTPA)
0.445; C9 stream PNCP shall be routed to second stage HDS of Prime
G unit. (100 KTPA).
LICENSOR
AXENS
FEED
RFCC Gasoline (C5-200) ASTM
On-stream Hours
8000
Yield pattern
COMPONENTS
Design WT%
Actual wt%
DESTINATION
FCC Gasoline
54.4
-
-
Light Coker Naphtha
30.5
-
-
C9 Cut
14.6
-
-
Hydrogen
0.5
-
-
H2S
0.1
-
F GAS
0.3
-
FG Header
LPG
0.5
-
LPG Pool
Product Naphtha
79.6
-
Gasoline Pool
C6 + Coker Naphtha
19.5
-
Naphtha Pool
Total
100
-
-
Feed
Product
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
Amine Absorption / SRU
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 41 of 62
Revamp of Prime G has been considered in this study. DCU light naphtha goes to a new DCU Light
naphtha splitter. Light cut from the splitter goes to the SHU section whereas ‘C6 + Coker Naphtha’ is
the heavy cut from new DCU light naphtha splitter located in revamped Prime G and routed to HGUs.
Yield & properties of LCN & HCN in the revamp scenario are given below:
Characteristics
Unit
LCN Cut
HCN Cut
14.5
53.6
614
765
IBP
17
67
5%
19
73
10%
20
77
30%
26
99
50%
34
134
70%
36
156
90%
42
176
95%
44
187
55
212
2.3
0.4
95
87
-
84
75.6
wt. ppm
8
8
wt. ppm
1
1
Tot-Paraffins content
vol %
39.9
36.3
Olefins content
vol %
59.7
19.3
Naphthenes content
vol %
0.4
5.1
Aromatics content
vol %
0.0
26
Negative
Negative
Not worse than 1
Not worse than 1
Flowrate
T/hr
o
Specific gravity@ 15 C
Kg/m
3
Distillation(ATM D-86)
FBP
o
RVP @38 C
2
Kg/cm a
RON
MON
Sulphur content tot.
(max)
H2S max
Doctor Test
Cu Stripper Test
RON, RVP and aromatics content of the HCN cut updated in consulation with client.
Utilities of Revamped Prime G


Power( KWH/Mt): 33
Steam : HP steam cons = 570.1 Kg/ Mt
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL










Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 42 of 62
LP Steam = 5.4 kg/Mt
Fuel Gas / Fuel Oil ( % SRF) : 0.08 Gcal/Mt
Cooling Water: 3.8 m3/Mt
Nitrogen:
Instrument Air
Plant Air
DM Water
Condensate: HP Condensate: 614.1 kg/Mt
LP Condensate: 5.4 kg/Mt
BFW: 44 kg/Mt
In the event of Prime G revamp, values of utilities consumed updated as provided by client.
M. DIESEL HYDRO TREATING UNIT (DHDS)
DHDT (DHDS)
CAPACITY( MMTPA)
0.55
LICENSOR
Axens
LGO from CDU-I & CDU-II, HGO from CDU-I, Vac Diesel from CDU-I and
CDU-II, LCO from RFCCU, LCGO from DCU
FEED
On-stream Hours
8000
Yield pattern
COMPONENTS
Design WT%
Actual wt%
Feed
100
100
H2
1.45
0.99
101.45
100.99
HYDROGEN SULFIDE
1.65
1.6
FUELGAS
0.13
NAPHTHA
1.02
1.63
AVU-1 NSU-2
DIESEL
97.5
97.06
HSD E-IV pool
Total
DESTINATION
Products
Fuel gas header
Loss
Total
Amine Absorber
0.7
100.3
Flare
100.99
DHDS feed max sulphur (1.699 %W), max cracked feed limit (w.r.t LCGO (10%) / Coker Naphtha
(0%W)/ LCO (10%)) (Total 20%W) as per design package.
DHDS sulfur in feed is to be maintained within 17000 wppm as per client.
No cracked feed is to be maintained to DHDS unit.
DHDS product properties:
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
STREAM
PROPERTIES
Design:
Naphtha
Actual
1.
Density @ 15 oC Kg/m3
750
Not
Available
2.
Sulphur
3.
Flash Point oC
4.
Cetane No.
SL. No.
<5000 ppm
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 43 of 62
Design:
Diesel
Actual
839
8 ppmw
40
110
24.4
52
IBP C
5% Rec.@ oC
161
174
188
205
o
202
217
Distillation
o
10% Rec.@ C
30% Rec.@ oC
-
o
5.
40% Rec.@ C
248
-
50% Rec.@ oC
269
278
o
70% Rec.@ C
-
o
90% Rec.@ C
332
333
95% Rec.@ oC
347
346
-
364
97%/ 98%
-
o
FBP C
Rec. %V @ 360/370 oC
6.
RVP
7.
Pour Point oC
0.63
-6
o
8.
Viscosity @ 38 C
3.2
9.
Nitrogen ppmw
10.
RON
68
11.
MON
67
12.
Cetane Index
20
58.8
13.
Aromatic (Vol %)
7
14.8
14.
Olefins (Vol %)
2
15.
Paraffins (Vol %)
58
16.
Naphthenes (Vol %)
35
17.
Benzene (Vol %)
2
Utilities





Cooling water ( M3/t of feed): 0.5
Power( KWH/Mt): 14.02
Steam : MP steam cons=133 Kg/ MT
Fuel gas/ Fuel Oil (Gcal / MT) : 0.042
Condensate(TPH) : 2.6
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL




Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 44 of 62
Nitrogen:
Instrument Air:
Plant Air
DM Water
N. FULL CONVERSION HCU
Full conversion HCU
CAPACITY(MMTPA)
1.7 (After Catalyst replacement, capacity is 1.9 MMTPA)
LICENSOR
UOP
FEED
VGO from CDU-I & II, HCGO from DCU
Slop from VDUs shall not be routed to because of limitation on arsenic
and other metals in feed as indicated by client.
8000
On-stream Hours
Cracked feed to HCU (to maintain nitrogen within limit) is maintained within 20 wt% of total feed as
confirmed by client.
Design: WT%
Actual
Present
Feed
100
100
H2
2.62
2.67
102.62
102.67
COMPONENTS
Total
Products
-
H2S+NH3
3.22+0.15
DESTINATION
3.39
SRU
FUEL GAS
0.34
LPG
2.20
3.08
LPG
LT.NAPHTHA
15.63
16.48
MSQ / PNCP
HV.NAPHTHA
1.61
4.28
HSD
-
-
-
KEROSENE
28.71
26.70
Kero / HSD / ATF
DIESEL
47.76
45.56
HSD
BOTTOM
3.00
3.18
FCC
102.47
102.67
NKSWNG
Total
FG Header
Stream property
STREAM
PROPERTIES
Sp Gravity
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
LT NAP.
Des
0.71
Act
0.702
NAPHTHA
Des
0.775
KERO
Act
BOTTOM
Act
Des
Act
Des
0.7699 0.8045 0.8019
0.840
0.838
0.845
[Type text ]
Des
DIESEL
Act
0.846
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
STREAM
PROPERTIES
LT NAP.
Des
Act
NAPHTHA
Des
KERO
Act
Des
Act
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 45 of 62
DIESEL
Des
BOTTOM
Act
Des
Act
Distillation
o
32
38
135
130
155
160
221
232
370
361
o
57
57
137
132
165
168
243
251
390
361
o
100
98
142
137
197
191
313
317
455
449
100% Rec@ C
129
130
147
156
222
221
370
360
540
504
N2 ppm Max
0.5
0.5
Benzene max %
1.5
0
RON
67
IBP C
10% Rec @ C
70% Rec @ C
o
1.0
2.0
15
MON
Sulfur (PPMW)
<5
RVP kg/cm2
3
<5
4
<5
5
<8
8
<50
0.09
0.07
Naphthenes vol%
36
60
58
52
40
Aromatics Vol%
4
6
11
8
7
Paraffins vol%
79
34
31
40
53
22
Olefin Vol%
0.05
max
Con carbon
Cetane Number
44
56
38
95
0.05
Cetane Index
Pour point Index
Viscosity
Flash Point
Paraffin content of Light naphtha stream changed to 79 vol% in consultation with client.
Utilities
 Power( KWH/Mt): 61.5
 Steam: HP steam cons = 189.6 Kg/ Mt, MP steam gen= 13.3 Kg/ Mt, LP steam gen =1137.8
Kg/ Mt;
 Condensate gen ( TPH) = 10 -12 MT/h
 Demin water (m3/hr) = 10 -12 MT/h
 Fuel Gas / Fuel Oil (Gcal/MT) : 0.2338
 Nitrogen:
 Instrument Air
 Plant Air
O. Bitumen Blowing Unit
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 46 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
BBU
CAPACITY(MMTPA)
0.5
LICENSOR
EIL
FEED
CDU-I & II Residue
On-stream Hours
8000
Yield pattern
COMPONENTS
WT%
ASPHALT
DESTINATION
99.8
For Sale
Utilities









Cooling water ( M3/t of feed):0.1
Power( KWH/Mt):3.75
Steam : MP steam cons = 41.7 kg/MT of feed, LP Steam Consumption= 473.7 Kg/MT
Fuel (Gcal/MT): 0.184
Nitrogen:
Instrument Air
Plant Air
DM Water
Condensate:
P. DELAYED COKER UNIT
DCU
CAPACITY(MMTPA)
3.0
LICENSOR
ABB LUMMUS
FEED
Residue from CDU-I&II, Vac Slop, CLO from RFCCU
On-stream Hours
8000
CCR in DCU is maintained max 25 wt%.
Yield pattern
Fuel Gas
3.64
Actual
Wt%
4.27
H2S
1.4
1.8
COMPONENTS
Design: WT%
0.4
C3= Propylene
C4 LPG
Template No. 5-0000-0001-T2 Rev. 1
Internal use
S recovery
0.92
C3 Propane
[Type text ]
DESTINATION
3.25
LPG/PRU
1.33
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 47 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
C5-120-LT NAPHTHA
6.94
Actual
Wt%
4.75
120-140 HV NAPHTHA
1.52
7.06
DHDT
140-370 LT GAS OIL
32.49
31.85
DHDT
370-540HV GAS OIL
20.26
15.56
HCU/OHCU
1.58*
FO
30.42
For sale
COMPONENTS
Design: WT%
FUEL OIL
30.51
GREEN COKE
DESTINATION
H2 Feed
*DCU actual yields include 1.58 wt% of fuel oil make, which is getting absorbed in either internal fuel oil or
fuel oil sales in base case. For expansion cases, since internal fuel oil make is not desirable and there is
no fuel oil sales, this quantity of fuel oil is to be absorbed in heavy gasoil from DCU.
Stream Properties
STREAM
PROPERTIES
LT
NAPHTHA
HV NAPHTHA
LT GAS OIL
HV GAS OIL
FUEL
OIL
Act
Des
Act
Des
Act
Des
Des
Act
0.7
0.6838
0.745
0.7648
0.854
0.8698
0.946
0.9528
0.965
0.9815
IBP
-
44
-
120
-
186
-
304
234
5%
48
48
124
123
161
208
365
387
335
10%
52
51
129
125
174
206
376
400
408
30%
-
-
-
-
-
-
-
-
-
50%
75
64
135
136
253
290
428
440
488
70%
-
-
-
-
-
-
-
-
-
90%
104
90
140
159
329
364
492
496
496
95%
115
98
146
166
344
386
494
510
510
EP
RVP @ 37.8°C,
123
130
151
179
359
>395
494
542
542
Des
Sp Gr.
2
kg/cm (RVP
Index available)
Pour Point,
°C PP Index
available)
Flash Point, oC
8.5
Olefin vol%
35.7
Aromatic vol%
0.9
-90.0
1.9
Total Sulphur (%
wt.)
RON
0.5
78
MON
73
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
Act
-10.0
36
-
20.0
<20
68.0
38.77
31.7
28.89
18
2.88
7.1
11.65
25
-
0.65
0.9
0.95
0
2.50
76.9
70
53.6
-
65
[Type text ]
77
90.0
4.4
>150
120
-
-
3.6
5
3.92
-
-
-
-
-
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
STREAM
PROPERTIES
LT
NAPHTHA
CCR (% wt.)
HV NAPHTHA
-
Cetane Number
Cetane Index (CCI)
-
20
LT GAS OIL
-
0.0120
28
36
42
45
Viscosity of CLO @
100 oC(cst)
Viscosity of CLO @
50 oC(cst)
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 48 of 62
HV GAS OIL
0.97
43.30
FUEL
OIL
1.09
5.24
-
-
6.7
67
300
For considering alkylation unit, composition of DCU LPG as provided by IOCL is as follows:
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 49 of 62
Utilities
 Cooling water ( M3/t of feed): 16.2
 Power( KWH/Mt): 16.7
 Steam : HP steam cons = 374.6 kg/MT of feed, MP steam generation = 263.7 kg/MT of feed,
LP Steam Consumption= 7.6 Kg/MT
 Fuel (Gcal/MT): 0.19
 Nitrogen:
 Instrument A
 Plant Air
 DM Water
 Condensate:
Q. DIESEL HYDRO TREATING UNIT-II (DHDT)
DHDT-II (DHDT)
CAPACITY(MM TPA)
3.5
LICENSOR
AXENS
FEED
SRLGO, SRHGO, SRK & SRVD from CDU/VDU-I/II, LCGO & CHN from
DCU
and LCO from RFCCU
8000
On-stream Hours
As per design package, maximum cracked feed limit (w.r.t LCGO (33%) / Coker Heavy Naphtha (1.4%) /
LCO (5.1%)) ( Total 39.4%W) is to be maintained.
PREP DHDT sulfur in feed is to be maintained within 17300 wppm.
Yield pattern
100.00
Actual
wt%
100.00
1.45
1.21
101.45
101.21
Sour Gas
2.51
2.20
PRE amine absorber
Stab. Naphtha
1.89
1.23
Naphtha pool / HGU-II feed pool / AVU-II stabilizer
Hydt. Diesel
97.05
97.63
HSD pool
Loss / Slop
0.00
0.15
101.45
101.21
COMPONENTS
Feed
H2 Make-up
Total
Total
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
Design wt%
DESTINATION
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 50 of 62
Stream properties
01
STREAM
PROPERTIES
Density Kg/m3
Design:
Naphtha
713
02
Sulphur ppmw
<5
03
Flash Point C
04
Cetane No.
SL. NO.
Actual
733.3
16
0
Design: Diesel
Actual
816
8 ( based on new
catalyst proposed)
47.1
824.5
55
8
50
55
Distillation
0
51.3
IBP C
54
0
0
54.9
10% Rec.@ C
95
0
165.5
198
0
40% Rec.@ C
0
77.4
50% Rec.@ C
116
0
256.4
277
292.0
70% Rec.@ C
0
90% Rec.@ C
0
95% Rec.@ C
0
107.6
144
339.4
338
122.8
170
367.6
360
189.6
FBP C
07
178
216.6
30% Rec.@ C
06
140
86
5% Rec.@ C
05
114.6
2
RVP kg/cm a
203
374.6
373
0.47
0
same as feed
Pour Point C
o
08
Viscosity cp @45 C
1.4
09
Nitrogen ppmw
<1
10
RON
65
11
MON
63
12
CETANE INDEX
13
AROMATIC (Vol %)
14
Olefins (Vol %)
15
Paraffins (Vol %)
16
Naphthenes (Vol %)
17
Benzene (Vol %)
<5
0.68
9.31
1
Utilities





Cooling water ( M3/t of feed): 0.5
Power( KWH/Mt): 14.1
Steam : MP steam cons= 133 Kg/ MT,
Fuel gas/ Fuel Oil (Gcal/MT) : 0.0269
DM Water ( m3/hr) : Peak)
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL




Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 51 of 62
Condensate ( TPH) :
Nitrogen:
Instrument Air
Plant Air
R. HGU-II
HGU-II
CAPACITY(TMTPA)
140
LICENSOR
HALDOR TOPSOE
FEED
Neat RLNG, Neat Naphtha or mix RLNG-Naphtha
On-stream Hours
8000
S.No
PROPERTY
Arab Mix S.R Naphtha Cut C5-140
Coker Naphtha C5-120
Total sulphur,
1
600
5900
ppmw
2 Naphthenes (vol %)
19
Acyclic-25.6
100 % capacity on a mixture of Straight Run Naphtha and Coker Naphtha. Maximum Coker naphtha to be
processed in HGU is 27 TPH.
Naphtha are processed through PDS unit, outlet sulphur content is 5 PPM max.
Note :
 The plant is designed to process 100% RLNG, and 50% RLNG+50% SRN & Coker Naphtha
cases
HGU can process coker naphtha/ SR naphtha/ RLNG in any proportion, provided sulfur in feed is
maintained within 5900 wppm.
Yield pattern
COMPONENTS
Design
wt %
Actual wt% RLNG
Actual wt% Naphtha
OFF GAS
68
64.1
67.57
H2
32
35.9
32.43
TOTAL
100
100
Destination
Gets consumed as
fuel in HGU internal.
Utilities
 Power ( KWH/MT) :57.3
 Steam : HP steam gen= 829 Kg/Mt, MP steam gen:850 KG/MT MLP steam gen:1606 KG/MT.
 DM Water ( M3/Hr):
 Cooling Water ( M3/ MT of Feed) : 33.5
S. PSU
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 52 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
PSU
CAPACITY(MMTPA)
0.357
LICENSOR
EIL
FEED
LPG from RFCC & DCU
On-stream Hours
8000
Yield pattern
COMPONENTS
Design WT%
100
Feed
LPG from RFCC & DCU
Actual wt%
DESTINATION
PSU or LPG pool
100
Yield
LPG
64
55.47
Propylene (C3 rich (65% propylene) gas)
34
43.34Panipat Naphtha Cracker PP unit
1.19
C2
LPG pool
FG header
100
Total
Utilities









Power( KWH/Mt): 15.36
Steam : LP steam cons = 1257 Kg/ Mt
Cooling water: 69.2 m3/T
Fuel Gas / Fuel Oil ( % SRF) :0
Nitrogen:
Instrument Air: 14.4 Nm3/hr
Plant Air: 56 Nm3/hr
DM Water
Condensate
T. PSA
PSA
CAPACITY(MMTPA)
Capacity of HGU-06 PSA is being used for Hydrogen recovery.
LICENSOR
UOP
FEED
H2 from CCR, FG from DHDT & OHCU (18000 NM3/hr)
On-stream Hours
8000
Yield pattern
COMPONENTS
Feed
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
WT%
DESTINATION
100
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
LPG from RFCC & DCU
100
FG Header
HIGH PURITY H2
47.600
H2 Header
FUELGAS
52.400
FG Header
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 53 of 62
Yield
Total
100
U. SRU-I
SRU-I (22 & 44)
CAPACITY(TPD)
115 x 2 (1W+1SB)
LICENSOR
M/s DHEL
FEED
H2S
On-stream Hours
8000
Note:
1) SRU 22 and 44 have only one incinerator in common. The incinerator has a capacity that can
cater to only one unit operation. Hence, the incinerator along with its associated facilities is an
impediment in parallel operations of SRU 22 & 44.
V. SRU-II with TGTU
SRU-II
CAPACITY(TPD)
225 x 3
LICENSOR
M/s BVPI
FEED
H2S
On-stream Hours
8000
W. AROMATIC COMPLEX
AROMATIC COMPLEX
CAPACITY (MMTPA)
FEED
On-stream Hours
0.709
Hy. Naphtha from OHCU (thru' NSU -2)& HCU, Straight run Heart Cut
Naphtha from AVU & AVU-II, and Naphtha from Mathura Refinery(PR
Naphtha, Mathura Naphtha and C7 &C8 from pygas)
8000
Yield pattern
COMPONENTS
AROM.FUEL GAS
AROM.
COMPLEX LPG
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
Design
WT%(revere)
12.2
Actual
wt%
15
2.2
3
DESTINATION
Internal consumption at PX complex
Refinery LPG pool
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Design
WT%(revere)
Actual
wt%
RAFFINATE (LIGHT
REFT.)
7.2
8
BENZENE
8.1
3.7
P-XYLENE
64.7
67
HV AROMATICS
Streams to MS
blending
TOTAL
2.8
3.7
COMPONENTS
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 54 of 62
DESTINATION
PNC Feed /MS pool
Stock transfer to Gujarat /Domestic
consumers/Export
PTA feed Stock
HSD
Reformate, Tatoray Feed & Slop as per
requirement
100.3
100
DESIGN:
Raffinate
(revamp)
662
ACTUAL
Raffinate(as
per BS 6)
Stream property
STREAM
PROPERTIES
Density @ 15 oC kg/m3
Distillation IBP oC
0% Rec @ oC
10% Rec @ oC
70% Rec @ oC
100% Rec @ oC
DESIGN
Heavy aromatics
(revamp)
880.7
ACTUAL
Heavy Aromatics
(As per BS6)
934.4
RON
76
38
50
95
128
0.1-0.5 (vol
%)
60.5
MON
73
Not Available
98
98
0.22
0.1
0.1
Benzene max vol %
16 PPM
Sulphur PPM
210
218
302 (@90%)
360 (@100%)
0.25PPM
0.25PPM (Note)
110
110
RVP kg/cm2
0.9
Not Available
0.6
0.6
Aromatics Vol%
0.05
0.03
100
100
0
0
Olefin Vol%
Cetane Number
30
Cetane Index
Flash Point
38
Benzene
Utilities





Power( KWH/Mt): 104.57
Steam : HP steam cons = 914.3 Kg/ Mt, MP steam gen after generation
consumption= 273 Kg/ Mt, LP steam generatio = 7.89kg/T
Cooling Water (m3/Ton) = 23.48
Condensate gen ( TPH) 660.16
REMARKS:
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 55 of 62
Benzene content in heavy reformate is maintained maximum 1.5 vol %.
X. Ethylene Recovery Unit:
Ethylene Recovery Unit
CAPACITY (MMTPA)
227.3 KTA (RFCC dry gas: 75.3 KTA, Coker
Dry Gas: 152 KTA)
LICENSOR
FEED
RFCC Dry gas and Coker Dry Gas
On-Stream Hours
8000
COMPONENTS
KTA
Design WT%
RFCC dry gas
75.3
33.13
Cooker dry gas
152
66.87
227.3
100
Refinery fuel gas
93.7
41.22
C2 product
81.9
36.03
C3+ products
37.2
16.37
Acid gas & water
14.5
6.38
Total
227.3
100
Feed
Total
Product
Product Composition:
C2 Product
Methane
Wt %
0
Ethylene
Wt %
20.4
Ethane
Wt %
78.9
Propylene
Wt %
0.6
Propane
Wt %
0.1
Ethane
Wt %
0
MAPD
Wt %
0.3
Propylene
Wt %
30.4
Propane
Wt %
C3+ product
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
28.9
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 56 of 62
Butanes
Wt %
9.3
Butenes
Wt %
13
Butadiene
Wt %
1.2
C4 Acetylenes
Wt %
0.1
C5+
Wt %
16.8
Hydrogen
Wt %
4
Nitrogen
Wt %
14.8
Carbon monoxide
Wt %
1.6
Methane
Wt %
74.1
Ethylene
Wt %
2.3
Ethane
Wt %
0
Propylene
Wt %
1.9
Propane
Wt %
1.2
Fuel gas
Utility consumption (consumption in T/T of feed):









Power consumption, kW : 4.0
Cooling water: 4.39
Instrument air: nil
Nitrogen: nil
LP steam consumption:0.318T
MP steam generation:1.70T
SHP steam consumption :1.70T
HP steam consumption:0.02
Fuel gas consumption: Nil
A common facility for ethylene recovery will be considered in the refinery complex, hence no new
Ethylene recovery unit will be considered in this study.
Y. TAME : 36 KTPA
Z. OCTAMAX:
Octamax unit can also be envisaged. Details shall be provided by IOCL subsequently.
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 57 of 62
AA. CPP
CAPACITY(MW)
LICENSOR
FEED
On-stream Hours
CPP
GT : 5 * 30 (5NO.S GT OF CAPACITY 30 MW EACH)
STG : 3 * 25 (3 NO.S STG OF CAPACITY 25 MW EACH)
TOTAL : 225 MW
BHEL
GT : NAPHTHA/RLNG
STG : VHP STEAM
8000 ( 4 GTS & 2 STGS OPERATION)
4.2 BS- VI Units
The Yield and product properties of the BS VI units to be taken as per Feasibility report for BS VI
Fuel Quality up gradation of Panipat refinery.




A. DHDT BS-VI
Feed and Constraint `similar to HGU-2 (unit 76/77). The plant to be designed for taking both RLNG
and Naphtha as feed and fuel at any proportion.
New DHDT max cracked feed limit (w.r.t LCGO (41.6%) / Coker Heavy Naphtha (8.9%) / LCO
(8.4%)) (Total 58.9%W) as per design package.
HGU can process coker naphtha/ SR naphtha/ RLNG in any proportion, provided sulfur in feed is
maintained within 5900 wppm.
BS-VI DHDT sulfur in feed is to be maintained within 18850 wppm.
B. PX-PTA
Yield pattern:
Design WT%
(after revamp)
12.2
Actual
wt%
13.03
AROM. COMPLEX
LPG
RAFFINATE (LIGHT
REFT.)
BENZENE
2.2
2.6
Internal consumption at PX
complex
Refinery LPG pool
7.3
7.5
PNC Feed /MS pool
8.1
3
P-XYLENE
HV AROMATICS
Streams to MS
blending
Hydrogen
64.7
2.8
-
56.09
3.6
11.5
2.7
2.7
COMPONENTS
AROM.FUEL GAS
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
DESTINATION
Stock transfer to Gujarat
/Domestic consumers/Export
PTA feed Stock
HSD
Reformate, Tatoray Feed etc as
per requirement
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
TOTAL
100
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 58 of 62
100
Stream properties:
“Streams to MS blending”:
S. No.
Parameters
Unit
Results
1
Density @ 15 oC
Kg/m3
2
Distillation
E-70
E-100
E-150
FBP
Residue
% Vol
% Vol
% Vol
o
C max
% Vol. Max
135
0.5
3
Sulphur, Total
mg/kg max
1
4
5
RON
MON
Min.
Min.
94
6
RVP @ 38 oC
kpa
54.8
785.4
12
55
VLI (10RVP+7E70)
7
Summer (May to Jul)
Max
8
9
10
Others
Benzene
Aromatics
Olefin
Max
% Vol-max
% Vol-max
% Vol-max
11
Existent Gum
g/m3-max
12
Gum(Solvent washed)
mg/100 ml max
13
Oxidation Stability
Minutes-Min
14
Lead as Pb
g/l-max
15
Oxygen content ,max
%wt-max
632
12.4
56.29
2.2
“Streams to MS pool” from PX block is to be made available for following routings:
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL



Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 59 of 62
To MS product blending
To fuel naphtha in HGU
Product sales at naphtha price
4.3 Additional utilities data provided by IOCL for PX-PTA
4.3.1 Post at 550 KTPA of PTA production
Power
140.5
Direct Fuel
HP
MP
LP
45.21
4.52
9.70
7.032
60.20
Power
KW/MT
MM
Kcal/hr
SRFT/hr
76.93
MT/hr
14.23 MW
4.3.2 PX-PTA post revamp to 700 KTPA of PTA production
Power
HP steam consumption
MP Steam generation
LP Steam generation
Cooling Water
Fuel
Condensate generation
140.5
914.3
273.0
7.9
23.5
0.76
660
KW/MT
KG/MT
KG/MT
KG/MT
M3/MT
Gcal/MT
KG/MT
4.4 Existing Storage Tanks
Refineries Tankage data of Crude Storage
Gross
Safe filling /
Tankage
Max holding
capacity(M
Capacity
Stream
Tank No:
T)
(MT)
Crude
Dead
Stock
(MT)
Net
Holding
(MT)
A
B
C
301-308
336000
285600
47463
D=BC
238137
LBT 04
34400
29240
5167.224
27991.6
LBT 06
34400
29240
6118.9
26885
LBT 10 & 11
68800
58480
16031.604
49358.6
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
Remarks
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
LBT 07 & 9
51600
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 60 of 62
43860
9104.992
40412.8
Gross
Tankage
Capacity
(MT)
Safe filling/
Max
holding
Capacity
(MT)
Dead
stock
(MT)
Net
holding
(MT)
A
B
C
5838
5254
117
D=BC
5137
3114
2802
183
2619
2929
2636
161
2475
11881
10693
461
10231
21-24
44100
37485
6732
30753
16
14700
12495
2414
10081
25-26
14903
12667
1895
10772
73703
62647
11041
51606
11,12,13
10575
8989
2249
6740
15
14100
11985
2381
9604
401
14100
11985
2162
9823
38775
32959
6793
26166
51,52,53,54
31,32,33,34,3
5
64000
54400
9101
45299
60000
51000
10809
40191
36
16600
14110
2656
13944
165000
140250
22559
117691
99000
84150
13969
70181
264000
224400
36528
187872
81,82,83,84
19000
16150
2040
14110
91-93
14250
12113
1591
10521
94 - 99
29400
24990
3182
21808
43650
37103
4773
32329
Refineries Tankage data of primary products
Product
LPG
Tank No.
HS 1 – 7
BULLET-1 &
2
BULLET-3 &
4
TOTAL
MS
TOTAL
NAPHTHA
TOTAL
SKO
ATF
ATF
HSD-III
HSD-IV
61,62,64,65,6
6
63, 67-68
TOTAL
FO
BITUMEN
TOTAL
Refineries Tankage data of Intermediate products/ stocks
Safe
Gross
filling/ Max
Dead
Tankage
Product
Tank No.
holding
stock
Capacity
Capacity
(MT)
(MT)
(MT)
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
[Type text ]
Net
holding
(MT)
Remarks
Tankage
holding is
approx qty.
Remarks
[Type text ]
Copyright EIL – All rights reserved
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
PX Feed
(Heart Cut
Naph)
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 61 of 62
A
B
C
D=B-C
14
3800
3230
775
2455
251-T01A/B
7600
6460
1182
5278
251-T01C/D
7600
6460
1182
5278
19000
16150
3140
13010
Total
CCR FEED
251-T-02
820
697
130
567
Reformate
251-T-03
4100
3485
522
2963
Tatoray Feed
251-T-04
3320
2822
446
2376
PX Day Tank
251-T-1A/B
2408
2047
385
1662
PIST Tank
PTA Feed
(PX)
205-T-3
1024
870
36
834
252-T10A/B/C
31216
26534
386
26148
DHDT Feed
403, 404,
405,406
99000
84150
13903
70247
DHDT Feed
406
16600
14110
2656
13944
502, 503, 504
46155
7813
38342
901, 902
54300
9215
7833
1744
6089
601, 602, 603
10350
8798
1873
6925
604,605, 606
21000
17850
3037
14813
OHCU Feed
PR HGU
Feed
PRE HGU
Feed
FCCU Feed
701, 702
34240
29104
4923
24181
402
18100
15385
2461
12924
501
17120
14552
2461
12091
4038
969
3069
74210
63079
10815
52264
29600
25500
117600
99960
11250
9563
1688
7875
2720
320
2400
15895
2805
13090
903
TOTAL
4750
COKER Feed
801,802,803,
804
904-907
SLOP
2001-2003
Mktng. SLOP
71-72
IFO
3001-3004
Isomerate
121
1650
1403
165
1238
Interphase
122
1650
1403
165
1238
Hy. KERO
MSQ NHT
Feed
IsomerateTan
k ISOM. Unit
111-112
304-TT-001/
304-TT-002
1620
1377
219
1158
13600
12995
2228
10767
10200
9662
528
9134
CRU Feed
304-TT-005
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
3200
18700
[Type text ]
4795
11780
Tankage
holding is
approx qty.
20705
88180
[Type text ]
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 4,Page 62 of 62
Basis of Study
Feasibility study for capacity expansion of
Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
4.5 EXISTING FEED RECEIPT AND PRODUCT DESPATCH FACILITIES
Table 4.5.1 : Crude & Product Receipt facilities
IOCL Pipelines
S. No.
Pipelines
Installed Capacity (MMTPA)
Product Pipelines
1
PBPL
Panipat Bhatinda Pipeline
1.5
2
PRPL
Panipat Rewari Pipeline
2.1
3
PAJPL
Panipat Ambala Jalandhar Pipeline
3.5
4
PDPL
Panipat Delhi Pipeline
3
5
PJPL
Panipat Jalandhar LPG Pipeline
0.7
6
PBAPL
Bijwasan Panipat Pipeline
3
Crude oil Pipelines
1
SMPL
Salaya Mathura Pipeline
7.3
2
MPPL
Mundra Panipat Pipeline
8.4
Table 4.5.2 : Product Loading / Unloading Gantry Facilities
Gantry No
Loading
Unloading
1
White Oil (MS/SKO/HSD3/ATF)
2
White Oil (MS/SKO/HSD3/Py- Gas)
3
FO
4
-
[Type text ]
Template No. 5-0000-0001-T2 Rev. 1
HSD4
Naphtha
[Type text ]
[Type text ]
Copyright EIL – All rights reserved
Market Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 5,Page 1 of 2
CHAPTER 5
MARKET STUDY
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Market Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
5.0
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 5,Page 2 of 2
MARKET STUDY
This section is excluded from the report as per scope of work.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Location
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 6,Page 1 of 2
CHAPTER 6
PROJECT LOCATION
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Location
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
6.0
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 6,Page 2 of 2
PROJECT LOCATION
The project P-25 is proposed at Panipat, Haryana. IOCL already operates a 15.0
MMTPA refinery along with PX-PTA and PNCP at the same location. The land required
towards the installation of the new units has already been acquired by IOCL adjoining
the refinery complex. Hence, cost towards land has not been considered as part of this
feasibility study.
The site is well connected by state highways and road network. The nearest important
town is Panipat city, which is approximately 15 Km from the site. The nearest airport and
rail junction from the site location are 135 Km and 18 Km away from the Panipat site
location respectively.
The indicative plot plan prepared for this project is attached as Annexure-2.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.1,Page 1 of 5
CHAPTER 7.1
PROJECT DESCRIPTION
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.1
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.1,Page 2 of 5
PROJECT DESCRIPTION
Panipat refinery, a unit of Indian Oil Corporation Limited (IOCL) operates a 15.0 Million
Metric Tons Per Annum (MMTPA) oil refinery at Panipat in Haryana. The refinery was
commissioned in 1997-98 and started off with a crude oil processing capacity of 6.0
MMTPA (PR- Panipat Refinery). The refinery capacity was raised to 12.0 MMTPA with
the addition of another crude unit and a full conversion hydrocracker as the secondary
processing unit and Delayed Coker unit for bottom processing (PREP- Panipat Refinery
Expansion Project). Through progressive revamps and addition of process units the
refining capacity has been brought to the present operating capacity of 15.0 MMTPA
(PRAEP- Panipat Refinery Additional Expansion Project). IOCL Panipat is also
integrated with Naphtha Cracker and Aromatic Complex.
The existing refinery consists of the following unitsTable 7.1.1
PANIPAT REFINERY (PR) UNITS
S.NO.
UNIT NAME
UNIT NO.
CAPACITY
LICENSOR
1.
2.
CDU, VDU
NSU-1 REVAMP
3
1.312 MMTPA
TECHNIP KTIL
3.
OHCU
5
1.9 MMTPA
UOP, IOCL
4.
HGU
6
38 KTPA
HALDAR TOPSOE
5.
RFCCU
7
0.85 MMTPA
SWEC,IOCL,EIL
6.
PSU
33
0.255 MMTPA
EIL
7.
CRU
8
IFP - AXENS
8.
DHDS
52
0.64 MMTPA
0.55 MMTPA
9.
VBU
9
0.4 MMTPA
EIL
10.
BBU
ATF MEROX (Converted
from Gasoline Merox)
LPG MEROX
10
0.5 MMTPA
EIL
12
30 m3/hr
UOP, IOCL, EIL
13
50 m3/hr
UOP, IOCL, EIL
ATF-KERO MEROX
SRU/SSRU ( Common
Incinerator)
ARU
15
180 m3/hr
22/44
115 TPD
21
400 m3/hr
UOP
DELTA HUDSON
- EIL
EIL
71.8 m3/hr
EIL
16.4 m3/hr
EIL
11.
12.
13.
14.
15.
16.
03, 04, 19
SWS-I (REFINERY)
17
SWS-II
17.
18
(HYDROPROCESSING)
PANIPAT REFINERY EXPANSION (PRE) UNITS
Template No. 5-0000-0001-T2 Rev. 1
7.5 MMTPA
(Based on BS VI - FR)
EIL,IOCL
IFP - AXENS
Copyright EIL – All rights reserved
Project Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
S No
UNIT NAME
1.
CDU, VDU
2.
NSU-2
3.
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.1,Page 3 of 5
UNIT NO.
CAPACITY
73, 74
7.5 MMTPA
EIL
59
0.72 MMTPA
TECHNIP KTIL
HGU
76, 77
2 X 70 KTPA
HALDER TOPSOE
4.
HCU
75
1.9 MMTPA
UOP
5.
DCU
78
3.0 MMTPA
ABB LUMMUS
6.
7.
COKER LPG MEROX
DHDT
79
0.1 MMTPA
UOP
72
3.5 MMTPA
AXENS
8.
SRU-I
55
225 TPD
BLACK & VEATCH
9.
SRU-II
56
TGU
225 TPD
EQ.450 TPD
SULPHUR
BLACK & VEATCH
10.
11.
ARU
51
12.
SWS-I (REFINERY)
53
13.
SWS-II (HYDROPROCESSING)
57
UNIT NAME
1.
NHT, CCR
2.
SHELL SULFOLANE
3.
PAREX
4.
UNIT NO.
201,
202, 203
204
BLACK & VEATCH
3
BLACK & VEATCH
3
EIL
410 m /HR
170 m /HR
54
40 m3/HR
PARA XYLENE AND PURIFIED TEREPHTHALIC ACID (PX and PTA) UNITS
S.NO.
LICENSOR
CAPACITY
MMTPA
EIL
LICENSOR
0.628
UOP
0.115
UOP
205
2.494
UOP
XFU
206
0.693
UOP
5.
ISOMAR
207
2.203
UOP
6.
TATORAY
208
0.624
UOP
7.
BTF
209
0.615
UOP
8.
PTA
221
DUPONT
9.
ERU
-
0.7
0.227 MMTPA
(Feed)
Thyssen Krupp
MS QUALITY UPGRADATION (MSQ) UNITS
S.NO.
1.
UNIT NAME
NHT /PENEX
UNIT NO.
301
2.
CAPACITY
410 / 400
TMTPA
470 TMTPA
RSU
302
FCC GDU
C9 stream PNCP shall be routed
3.
303
445 TMTPA
to second stage HDS of Prime G
unit. (100 KTPA).
PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT (PRAEP) UNITS
S.NO.
UNIT NAME
UNIT NO.
CAPACITY
3
LICENSOR
UOP
IFP - AXENS
AXENS
LICENSOR
1.
SWS
20
40 m /HR
EIL
2.
SRU-III
25
225 TPD
BLACK & VEATCH
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
3.
TGU
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.1,Page 4 of 5
26
EQ.450 TPD
SULPHUR
BLACK & VEATCH
UNIT NO.
CAPACITY
LICENSOR
BS-VI UNITS
S.NO.
UNIT NAME
1.
DHDT
-
2.2 MMTPA
UOP
2.
HGU
-
44 KTPA
-
3.
SRU
-
225 TPD
Prosernet
4.
TAME
-
36 KTPA
-
5.
ARU
-
189 m3/hr
EIL
6.
SWS (Hydroprocessing)
-
7.
Octamax
-
3
56.7 m /hr
Not to be
considered in base
case
EIL
IOCL R&D
M/S IOCL is considering to increase the processing capacity of the existing refinery from 15
MMTPA to 25 MMTPA. IOCL has entrusted M/S EIL to carry out a configuration study and
preparation of feasibility report with a cost estimate of +30% for capacity expansion of
Panipat Refinery Expansion from 15 MMTPA to 25 MMTPA and screening
of various
configuration options for the proposed capacity enhancement based on preliminary
economics (GRM and Simple payback period). Detailed analysis of the two shortlisted
cases is done and recommended case is selected.
7.2 Methodology adopted
The methodology adopted for arriving at the most optimum refinery configuration is as
below:

With the objective of meeting the guidelines established in Auto Fuel Policy 2025
wherein it would be required to manufacture 100% BS-VI fuels, a study was carried out
by M/S EIL in March, 2016 (for existing refinery – 15.0 MMTPA) to analyze the potential
for conforming to the mandate as described above by 2020 as envisaged by Govt. of
India . This LP model for BS VI study is used as base case for this configuration study.

Expansion study is performed with the design crude mix, feed and product properties as
provided in the design basis and agreed by client.

Various options for secondary and bottom processing units are analysed in concurrence
with client.

Total 20 configuration cases were studied to arrive at the most optimum configuration.

Selected configuration is subjected to further detailed study and financial analysis.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.1,Page 5 of 5
7.3 Utilities system
The following utility systems are considered in this study:
1.
2.
3.
4.
5.
6.
7.
8.
Compressed air
Nitrogen
Cooling water
Water system
Steam
Flare and ETP
Power import
Fuel
7.4 Deliverables
Following are the main deliverables as part of this feasibility report:
 Executive Summary
 Introduction
 Scope of work
 Basis of study
 Details of the configuration study which includes the product pattern, capacity of
new units, GRM and analysis of the various configurations to arrive at the
shortlisted configurations.
 Detailed analysis of the selected case with material balance, Capacity of new
unit, Utilities and offsite requirements, plot plan, detailed cost estimates and
financial analysis.
 Process Description of the new units.
 Sulphur and Hydrogen Balance for the selected case.
 Environmental Considerations for the Selected Case.
 HSE requirements for the selected case.
 Block Flow Diagram for the selected case.
 Project Schedule.
 Costing Sheets.
 Conclusion and Recommendation.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 1 of 79
CHAPTER 7.2
REFINERY CONFIGURATION STUDY
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 2 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.2
DEVELOPMENT OF REFINERY CONFIGURATION
The most optimum project configuration is established by using linear programming. The steps adopted and the methodology followed
for arriving at the most optimum refinery configuration for the Panipat refinery expansion is discussed in this section.
7.2.1
Configuration Study Approach initially considered
The methodology initially proposed for arriving at the most optimum refinery configuration is described below:














LP Model of the existing refinery at 15 MMTPA for 100% BS VI fuels was developed by EIL in March, 2016. This is considered
as base case for refinery expansion from 15 MMTPA to 25 MMTPA.
BS VI base case is updated by incorporating additional TAME unit, revamped Prime-G, PX-PTA, change in PNCP shared
streams. These new units coming under BS VI project are considered as available for P-25 expansion.
Configuration study is performed with the Design case crude mix.
LP Model runs are taken at 3 year average prices from April, 2014 to January, 2017 for crude and products.
All the new facilities coming under expansion have considered RLNG and internal fuel gas as fuel. Also, IFO firing in all the
existing refinery and PX-PTA heaters will be replaced by RLNG firing in the expansion cases.
Value added products like LOBS,LAB, PET, Ethylene etc considered to improve IRR.
Zero liquid effluent discharge from new facilities is considered.
Plot plan of BS VI project to be considered for the expansion study FR.
New flare stack is demountable.
Flexibility to shift from HSD to gasoline maximization and vice versa is considered.
All the new facilities are considered and being sourced from grid. For selected case, a sensitivity analysis considering captive
power generation shall be done.
Various options are analyzed to find out the best refinery configuration which shall meet the objectives of the study.
Configuration screening is carried out based on gross margins, comparative capital cost involved, simple payback periods and
pros & cons of each new technology considered.
Selected Configuration option was subjected to further detailed study and rigorous financial analysis to arrive at the most
optimum refinery configuration.
7.2.1.1
LP Model
General
EIL uses PIMS (Process Industry Modelling Systems) LP Software to develop the comprehensive LP Model of Refinery.
Linear Programming (LP) is a mathematical technique for determining the most optimum allocation of resources to achieve a
particular objective when there are alternative uses for the resources. Optimizing the operation of refinery or the determination of
the optimal configuration is a typical application of linear programming. The refinery is described by a set of given equations and/
or inequalities (m) involving variables (n), and solved by finding the non-negative values of these variables which satisfy the
equations and inequalities and also maximize the objective function or profit. This analysis involved the creation of a model that
represented nearly 2000 equations and/or inequalities and more than 2000 variables.
The Equations represent: Feed availability, plant capacity and possible stream routings.
The Variables represent: Amount of feeds purchased and products made, operating variables and actual stream disposition.
The Objective function is being maximized, typically product value less raw material and operating costs.
Overview of LP model
The following sections briefly describe the input data (and its source) and alternate stream dispositions. These greatly affect the
final results of the LP Model.
The LP model developed uses mostly weight based units and some volume based units to better handle the material balance
around the refinery complex. The whole model operates on a weight basis.
The architecture of the LP model can be broadly defined by the following key components. As a matter of convention these are
labelled as ‘Tables’.
 Buy & Sell tables (Feeds, Products & Utilities)
 Assay tables/Distillation tables (Crude assay and crude unit product yields & properties)
 Sub-model tables.
 Blends tables(Product blend specifications, Blend mix)
Various other tables for defining various constraints and inputs are available but are not detailed in this report. The following
pages describe briefly the importance of the above tables in the overall LP optimization.
Buy & Sell Tables
These tables define the maximum & minimum quantities of feeds/utilities permitted for purchase and also that of products
permitted for sales. The prices of these streams are also defined here. Products which are selling on volume basis in actual
refinery operations, prices were given in Rs/KL and products which are selling on weight prices were given on Rs /MT basis.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 3 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Sub-model Tables
Sub-models are the building blocks of an LP model. All the process units and utility producing units are represented by various Submodels. The optimizer tool optimizes the interaction between the various sub-models and other tables and thereby creates a “flow”
between sub-models. This flow between sub-models eventually results in an optimized configuration scheme.
Given below are the major sub-models in LP.
Process Unit Submodel
Process unit sub-models require yields which are either in weight or volume basis. Weight based yields have been used for all the
process sub models. Typically the yields have been given in the following format:
 Base Yield for every unit
 Delta yields as required.
a) Crude Assay & Crude/Vacuum distillation Unit
The Crude/vacuum unit is not a sub-model in LP but is defined in Assay tables. However, for the sake of simplicity it is described as a
submodel.
Assay data provided by IOCL has been used to generate yields and properties for various cut points as envisaged.
Crude and Vacuum units are modelled in single submodel. Utilities for all the units are also considered.
b) Utility Submodel
The Utility submodel produces all the utilities required by process units. Utility requirements for each process unit are defined in
respective process submodel. Except raw water all other utilities required for each of the configuration are produced in the utility model.
Accurate utility estimates are essential to predict the fuel & loss of the refinery complex and also operating costs. In this study the utility
requirements considered are annualized operating utility requirements.
Utilities typically tracked in by LP model are:
 Power, (KWh)
 Steam (MT)
 Fuel (fuel gas or fuel oil in terms of MMKcal/hr)
 Catalyst & chemicals (Rs)
Utility requirement is entered in the LP model in one of the following ways.
 Unit of feed (weight or volume, for example for power KWH/ton of feed processed)
 Unit of product (weight or volume, for example in H2 plant KWH/ton of H2 produced)
c) Captive Power plant
Power & steam are generated in the captive power plant (CPP) submodel. Power plants such as GT, STG and Utility boilers are
modelled based on Steam and Power integration report done by EIL and in-house data available. However, the final power and steam
balances are carried outside the LP model.
d) Refinery fuel balance
Refinery fuel is another important utility tracked by the LP model. Refinery Fuel requirement is met by refinery fuel gas and internal fuel
oil .Fuel requirement is defined in each process sub-model and hence total refinery fuel requirement is known in terms of MT of fuel oil
equivalent/Annum.
e) Sulphur Recovery unit
Sulphur recovery of existing SRUs is considered as 99.9 % along with Tail Gas Treating Unit to reduce the overall SOx emissions.
However, the final sulphur balance and estimation of SRU capacity are carried outside the LP model.
Product Blending
The following blend tables are configured as part of LP model development:
 Blend Mix: Defines the streams that are allowed for blending to produce the desired product.
 Blend properties: Defines the properties of various blend streams identified for blending in Blend Mix table
 Blend specs: Defines the product specifications required to be achieved by LP model.
Based on the above considerations LP model is developed and various configuration options for the refinery expansion are worked out
for further analysis and screening.
7.2.1.2 Refinery Economics
For each case as estimated by LP model, refinery economics is worked out as follows:
 The refinery gross margin which is equal to product revenues minus feedstock costs is calculated for base case and expansion
cases. Incremental GRM i.e. Expansion cases GRM minus base case GRM is used for economic analysis.
 The refinery variable operating costs estimated by LP model. Variable operating cost include the cost of providing catalyst and
chemicals in support of ongoing refinery operations These operating costs for catalysts & chemicals are furnished in each process
sub model. These costs are based on in-house data and licensors data.
 The cost of purchasing utilities is also included in variable operating costs. However, all the utilities required for this project are
generated internally. Raw water is the only purchased utility and the cost is based on pricing data supplied in LP model.
 These variable costs are subtracted from the gross margin to yield, in turn, the net refinery operating margins.
 Total project cost for expansion is estimated outside LP model using in-house spread sheet based model.
 The components involved in estimation of total project cost are:
 New Process Unit Cost
 New steam-power system Cost
 Offsite & Utilities
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL






Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 4 of 79
Miscellaneous (Roads, Buildings, Township, Construction Expenses, Non Plant Builds)
EPCM Charges
Licensor Royalty Charges
BDEP Charges
1st Charge Of Catalyst
Contingency
The basis for each of the above components used is explained below:
 Capital cost for the new unit estimated based on large in-house data/ licensors data and appropriately applying capacity factors for
each case.
 Based on the above the total new process units cost is estimated.
 New steam system cost is estimated based on gross steam produced/consumed in refinery. The cost data is based on estimated
steam system configuration and in-house data.
 Utilities & offsite costs are estimated based on in-house data.
 Summation of Process unit costs and utilities & offsite costs result in Plant & Machinery cost.
 Miscellaneous costs including roads, buildings are estimated based on in-house data.
 Licensor Royalty charges, BDEP fees and costs for 1st charge of catalyst are estimated based on in-house data.
 Contingency of 10% is considered reasonable at this stage of the study.
 Payback period is estimated by dividing the total project cost with actual refinery margin.
 Based on the preliminary economic summary the configuration screening is carried out to eliminate the various options studied.
7.2.2
Base Case
LP Model of the existing refinery at 15 MMTPA for 100% BS VI fuels is considered as the base case of the refinery expansion study
from 15 MMTPA to 25 MMTPA. All new facilities in BS VI project i.e. additional TAME unit, revamped Prime-G, PX-PTA, change in
PNCP shared streams are considered as available for the expansion configuration study.
7.2.2.1 Key Considerations for Base Case
Following are the key considerations for the base case:

BS VI project is considered as executed for the expansion case study. Hence the following facilities are considered as available:
Table 7.2.2.1.1: Capacity of BS VI units
Unit
Capacity (Design)
DHDT
2200 KTPA
HGU
44 KTPA
Sour water Stripper (2 stage)
56.7 m3/hr
ARU (MDEA based)
189 TPH
SRU + TGTU
225 TPD
Additional considerations are as follows:






100% BS VI fuels production.
SOx have been limited to 1000 Kg/hr (excluding PXPTA/PNCP).
Naphtha from refinery to PNCP shall be minimum 60% of 2910 KTPA (1746 KTPA) of the total naphtha requirement in PNCP
(2910 KTPA). These naphtha sales from refinery shall be evaluated at 3 year average price.
Fuel gas from RFCC and DCU to be routed to PNCP for ethylene recovery at fuel gas price.
There is no production of Premium gasoline for base case due to less price differential between regular and premium MS.
For all the existing and new units, number of stream hours will be 8000hrs/yr.

Price of PFO from PNCP shall be considered as same as price of high sulphur fuel oil.






Aromatics of C7-C8 stream from PNCP updated to 75 vol% in consultation with client.
RON, RVP and aromatics for Prime G product updated to 87, 0.4 kg/cm2 A and 26 vol% respectively in consultation with client.
RON and RVP for isomerate updated to 87 and 1.0 kg/cm2 A in consultation with client.
C-9 shall be routed only to prime G unit in order to saturate the revamped capacity of Prime G. Bottom streams from new DCU
light naphtha splitter located in revamped Prime G is routed to HGUs.
C7-C8 stream from PNCP to refinery shall be considered as 228 KTPA for base as well as expansion cases.
Paraffins in Full conversion hydrocracker light naphtha are same as that for paraffins in OHCU light naphtha, i.e. 79 vol%.

Sulfur in feed to be limited to following:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 5 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Table 7.2.2.1.2 : Sulphur Limits in feed
S.NO
UNITS
SULPHUR LIMITS (WPPM) IN FEED
1
HGU-1
200
2
HGU-2
5900
3
HGU-3
5900
4
DHDS
17000
5
6
PREP DHDT
BS-VI DHDT
17300
18850
7
NHT FOR CCR
700
 Following limits in feed are to be maintained in DHDTs:
Table 7.2.2.1.3: wt % of feed in DHDT
S.NO
COKER DIESEL (wt% of
feed )
UNITS
RFCC DIESEL (wt% of
feed)
COKER NAPHTHA (wt% of feed)
1
PREP DHDT
33
5.1
1.4
2
BS-VI DHDT
41.6
8.4
8.9
7.2.2.2 Feed and product prices
Feed and product prices were initially considered based on 3 year average price from April, 2014 to January, 2017.
Table 7.2.2.2.1: Feed Prices (April, 2014 to January, 2017)
3 Years Average
Streams
(Rs/MT)
2014-2017 (Jan'17)
Mangla
25,535
Bonny Light
31,673
Basrah Heavy
24,537
Basrah Light
26,717
Kuwait
27,549
Maya
22,591
Saturno
27,816
Arab Mix( 80: 20)
28,318
Arab Mix( 50: 50)
27,576
Escravos
31,641
Forcados
31,371
Iran MIX (75:25)
28,558
Quaiboe
32,533
Zafiro
29,857
Bombay High
30,685
C4 LPG
31,165
C7 to C8 streams from PNCP
40,599
C-9 Streams from PNCP
34,637
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 6 of 79
3 Years Average
Streams
(Rs/MT)
2014-2017 (Jan'17)
(if routed to HSD)
C-9 Streams from PNCP
40,599
(if routed to MS)
C-5 Streams from PNCP
40,599
RLNG (Rs/MT)
37915
Methanol (Rs/MT) for TAME unit
13,860
Table 7.2.2.2.2: Product Prices (April, 2014 to January, 2017)
3 Years Average
Streams
(Rs/MT)
2014-2017 (Jan'17)
Fuel gas
24,244
LPG
31,165
Ethylene
-
Propylene
42,021
MS BS VI Regular
40,599
MS BS VI Premium
45,302
SKO
35,508
ATF
34,825
HSD BS VI
34,637
HSFO
22,322
Bitumen VG30
24,056
Sulphur
6,300
Coke
5,413
PNCP Naphtha (EPP)
31,111
PTA
41,913
GR-II H-150 BS
68,703
GR-II H-500
47,874
GR-II H-150
43,250
GR-II H-70
38,771
LAB
68,993
PET
46,900
Benzene
50,119
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 7 of 79
7.2.2.3 Material balance of base case
Material balance of base case based on 3 year average prices from April, 2014 to January, 2017.
Table 7.2.2.3.1: Feedstock Purchases (KTPA)
FEEDSTOCK PURCHASES
Crude blend
LNG
MATHURA REF. NAPHTHA
AIR FOR PTA
C7-C8 FROM PNCP
C9+ STREAM FROM PNCP
FUEL OIL FROM PNCP
C4 FROM PNCP
C5 FROM PNCP
SURPLUS H2 AVAILABLE
METHANOL TO TAME UNIT
KTPA
15000.0
257.2
150.0
236.4
228.0
100.0
112.0
200.0
170.0
6.8
10.6
Table 7.2.2.3.2: Product Sales (KTPA)
PRODUCT SALES
MIXED LPG'S
RFCC PROPYLENE
FUEL GAS FROM RFCC AND DCU
BS-VI REGULAR GASOLINE
BENZENE
PARA XYLENE
PTA
TOTAL NAPHTHA TO PNCP
ATF
BS- VI HSD
HIGH SUL.F.OIL
BITUMEN
COKE
PRODUCT SULPHUR
REF. TOTAL LOSSES
KTPA
654.9
110.8
1.2
1638.5
24.5
0.3
700.0
1746.0
1125.0
7395.9
225.0
360.0
869.5
168.2
1451.9
7.2.2.4 Base case GRM
GRM of the base case based on 3 year average prices from April, 2014 –January, 2017 is as follows:
Table 7.2.2.4.1 : Base Case GRM
GRM
Gross Margin
Rs Cr/Annum
2803.7
7.2.2.5 Revised Feed and Product prices
Feed and product prices were taken considering 3 years average price for the period of April, 2014 –January, 2017. However, subsequently
prices were revised for the period of April, 2014-March, 2017.Followwing table shows the price differential between the 3 year average price
considered for April,2014-March,2017 and April,2014-January,2017.
Table 7.2.2.5.1: Price Differential for 3 year average prices considered
Mangla
Bonny Light
Basrah Heavy
Basrah Light
Kuwait
Maya
Saturno
Arab Mix( 80: 20)
Arab Mix( 50: 50)
3 year average price till MARCH 2017
(Rs/MT)
3 year average price TILL
JANUARY 2017 (Rs/MT)
Price differential
(Rs/MT)
26,094
32,154
25,134
27,388
28,218
23,155
28,322
28,866
28,102
25,535
31,673
24,537
26,717
27,549
22,591
27,816
28,318
27,576
559
481
597
671
669
564
506
548
526
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 8 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Escravos
Forcados
Iran MIX (75:25)
Quaiboe
Zafiro
Bombay Hi
C4 LPG
32,128
31,808
29,147
33,062
30,401
31,218
35446
31,641
31,371
28,558
32,533
29,857
30,685
31,165
487
437
589
529
544
533
4,281
C7 to C8 streams from PNCP
43783
40,599
3,184
C-9 Streams from PNCP
(if routed to HSD)
37808
34,637
3,171
C-9 Streams from PNCP
(if routed to MS)
43783
40,599
3,184
C-5 Streams from PNCP
43783
40,599
3,184
PFO from PNCP
23946
22,322
1,624
RLNG (Rs/MT)
METHANOL
Naphtha Ex. Mathura
Naphtha Ex. Gujarat
Naphtha Ex. Barauni
38395
480
720
2656
2844
37915
13,860
720
2656
2844
Naphtha Ex. Bongaigaon
3818
3818
0
Naphtha Ex. Haldia
Fuel gas
LPG
Ethylene (1 YEAR PRICE)
Propylene
MS BS VI Regular
MS BS VI Premium
SKO
ATF
HSD BS VI
HSFO
Bitumen VG30
Sulphur
Coke
PNCP Naphtha (EPP)
PTA
3561
22959
35446
34574
47822
43783
45506.8
39378
38712
37808
23946
25986
7418
5115
31369
42145
3561
24,244
31,165
34574
42,021
40,599
45,302
35,508
34,825
34,637
22,322
24,056
6,300
5,413
31,111
41,913
0
-1,285
4,281
0
5,801
3,184
205
3,870
3,887
3,171
1,624
1,930
1,118
-298
258
232
GR-II H-150 BS
GR-II H-500
GR-II H-150
GR-II H-70
MEG
PET
Benzene
68795
48259
43468
39009
47400
63231
51638
68,703
47,874
43,250
38,771
46,900
46,900
50,119
92
385
218
238
500
16,331
1,519
LAB
85828
41430
44398
0
0
0
Lubes
The utility import prices have been considered as follows:
Table 7.2.2.5.2 - Utility Price
PRODUCTS
UNIT
Power
Rs/KWH
Raw water
RLNG
Rs/m
3
Rs/MT
PRICE
8.45
13.49
31017
7.2.2.6 Material Balance
a) Material balance for the base cases with revised prices is tabulated below:
Table 7.2.2.6.1: Material balance
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
FEEDSTOCK PURCHASES
KTPA
Crude blend
15000.0
LNG
1067.5
C7-C8 from PNCP
228.0
C9+ STREAM from PNCP
100.0
FUEL OIL from PNCP
112.0
C4 from PNCP
200.0
C5 from PNCP
170.0
SURPLUS H2 AVAILABLE
6.8
MATHURA REF. NAPHTHA
150.0
AIR FOR PTA
239.5
METHANOL TO TAME UNIT
9.6
TOTAL
17283
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 9 of 79
635.9
MIXED LPG'S
PROPYLENE FROM EXISTING REF
112.5
FUEL GAS FROM EXISTING REF
89.0
BS-VI REGULAR GASOLINE
1688.2
BENZENE
24.6
PTA
700.0
TOTAL NAPHTHA TO PNCP
1970.4
ATF
1125.0
BS-VI HSD
7733.8
HIGH SULPHUR FUEL OIL
225.0
BITUMEN
360.0
COKE
908.9
PRODUCT SULPHUR
142.4
REF. TOTAL LOSSES
1567.6
TOTAL
17283
b) Power Import
Power import for the base case is tabulated below:
Power import
UOM
Base case
MW
6.2
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 10 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.2.2.7 Unit Capacity Utilization
The capacities of various existing units were provided by IOCL, which are based on maximum sustainable operation achieved for each.
These capacities are considered as available for Base Case as well as expansion cases. Capacity of each existing unit capacity is
tabulated in table 7.2.2.7.1 below:
Table 7.2.2.7.1: Capacity of Existing Units
PANIPAT REFINERY (PR) UNITS
S.NO.
UNIT NAME
UNIT NO.
1.
CDU, VDU
03, 04, 19
2.
NSU-1 REVAMP
3
1.312 MMTPA
TECHNIP KTIL
3.
OHCU
5
1.9 MMTPA
UOP, IOCL
4.
HGU
6
38 KTPA
HALDAR TOPSOE
5.
RFCCU
7
0.85 MMTPA
SWEC,IOCL,EIL
6.
PSU
33
0.255 MMTPA
EIL
7.
CRU
8
IFP – AXENS
8.
DHDS
52
9.
VBU
9
0.64 MMTPA
0.55 MMTPA
(Based on BS VI - FR)
0.4 MMTPA
10.
BBU
ATF MEROX (Converted from Gasoline
Merox)
LPG MEROX
10
0.5 MMTPA
EIL
12
30 m3/hr
UOP, IOCL, EIL
13
50 m3/hr
UOP, IOCL, EIL
11.
12.
CAPACITY
LICENSOR
7.5 MMTPA
EIL,IOCL
3
IFP – AXENS
EIL
13.
ATF-KERO MEROX
15
180 m /hr
14.
SRU/SSRU ( Common Incinerator)
22/44
115 TPD
15.
ARU
21
400 m3/hr
UOP
DELTA HUDSON
- EIL
EIL
16.
SWS-I (REFINERY)
17
71.8 m3/hr
EIL
17.
SWS-II (HYDROPROCESSING)
18
16.4 m3/hr
EIL
PANIPAT REFINERY EXPANSION (PRE) UNITS
S No
UNIT NAME
UNIT NO.
CAPACITY
LICENSOR
73, 74
7.5 MMTPA
EIL
59
0.72 MMTPA
TECHNIP KTIL
1.
CDU, VDU
2.
NSU-2
3.
HGU
76, 77
2 X 70 KTPA
HALDER TOPSOE
4.
HCU
75
1.9 MMTPA
UOP
5.
DCU
78
3.0 MMTPA
ABB LUMMUS
6.
7.
COKER LPG MEROX
DHDT
79
0.1 MMTPA
UOP
72
3.5 MMTPA
AXENS
8.
SRU-I
55
225 TPD
BLACK & VEATCH
9.
SRU-II
56
225 TPD
BLACK & VEATCH
10.
TGU
57
EQ.450 TPD SULPHUR
BLACK & VEATCH
11.
ARU
51
410 m /HR
BLACK & VEATCH
12.
SWS-I (REFINERY)
53
170 m3/HR
EIL
13.
SWS-II (HYDROPROCESSING)
54
PARA XYLENE AND PURIFIED TEREPHTHALIC ACID (PX and PTA) UNITS
S.NO.
UNIT NAME
1.
NHT, CCR
2.
SHELL SULFOLANE
3.
PAREX
4.
UNIT NO.
201,
202, 203
204
3
3
40 m /HR
CAPACITY
MMTPA
EIL
LICENSOR
0.628
UOP
0.115
UOP
205
2.494
UOP
XFU
206
0.693
UOP
5.
ISOMAR
207
2.203
UOP
6.
TATORAY
208
0.624
UOP
7.
BTF
209
0.615
UOP
8.
PTA
221
0.7
DUPONT
-
0.227 MMTPA (Feed)
Thyssen Krupp
9.
ERU
MS QUALITY UPGRADATION (MSQ) UNITS
S.NO.
UNIT NAME
UNIT NO.
CAPACITY
LICENSOR
1.
NHT /PENEX
301
410 / 400 TMTPA
UOP
2.
RSU
302
470 TMTPA
IFP – AXENS
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 11 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
3.
FCC GDU
C9 stream PNCP shall be routed to second stage
HDS of Prime G unit. (100 KTPA).
303
445 TMTPA
AXENS
PANIPAT REFINERY ADDITIONAL EXPANSION PROJECT (PRAEP) UNITS
S.NO.
UNIT NAME
UNIT NO.
CAPACITY
LICENSOR
25
40 m3/HR
225 TPD
BLACK & VEATCH
26
EQ.450 TPD SULPHUR
BLACK & VEATCH
UNIT NO.
CAPACITY
LICENSOR
1.
SWS
20
2.
SRU-III
3.
TGU
EIL
BS-VI UNITS
S.NO.
UNIT NAME
1.
DHDT
-
2.2 MMTPA
UOP
2.
HGU
-
44 KTPA
-
3.
SRU
-
225 TPD
Prosernet
4.
TAME
-
36 KTPA
-
5.
ARU
-
189 m3/hr
EIL
6.
SWS (Hydroprocessing)
-
7.
Octamax
-
7.2.2.8
3
56.7 m /hr
Not to be considered in base
case
EIL
IOCL R&D
Gross Refinery Margin
Based on the revised prices of crudes and products as given in the Table 7.2.2.8.1 and quantities of crude and products as listed above in
Table, gross refinery margin for the base case is summarized below in Table:
Table 7.2.2.8.1 Gross Refinery Margin- Base case
Economic Parameters
Base Case
5448.8
Gross Refinery Margin (Rs Crores / Annum)
7.4
Gross Refinery Margin (US $/ bbl of Crude)
7.2.2.9 Key Findings
The key finding for the base case are:
 Power import made open in base case due to increased power requirement.









CCR in RFCC is maintained between 1 wt % to 1.5 wt %.
CCR in DCU is maintained max 25 wt%.
Cracked feed to OHCU and HCU is maintained within 20wt% of total feed to maintain nitrogen limit in the feed.
Slop from VDUs is not routed to existing HCU’s because of limitation on arsenic and other metals in feed to these units.
DCU light naphtha is routed to new splitter in revamped Prime G unit, and DCU heavy naphtha is routed to DHDT unit.
OHCU heavy naphtha may be routed to CCR. Full conversion HCU heavy naphtha is to be routed to diesel.
OHCU/ FC-HCU light naphtha is not be routed to ISOM.
Minimum density specification for BS-VI Diesel is to be removed in line with latest BS-VI gazette notification from govt.
HGU’s (existing and new) can be operated on naphtha or RLNG feed, whichever is economical. RLNG and naphtha in any proportion
can be used as feed to reformer in all three hydrogen generation unit. HGU 76, 77 can use only naphtha as fuel.
 All GT’s to be operated only on RLNG feed.
 Since the price of RLNG provided is high, eliminating internal fuel oil (max sulphur of 0.5 wt. %) will lead to drop in GRM for expansion
cases. Hence replacement of entire refinery fuel to refinery fuel gas and RLNG is not be considered.
 Prices considered are based on 3 year Average price (April, 2014 – March, 2017).
7.2.3
Refinery Configuration Study for 25 MMTPA refinery capacity
Refinery configuration study is performed to establish the material balance and unit capacities for 100% BS VI quality fuels production at
refinery capacity of 25 MMTPA.
Original Design case crude mix identified for this study is as tabulated below:
Table 7.2.3.1 Design case crude mix
Crudes
Bonny Lt.
Design Case
(MMTPA)
0
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 12 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Basrah blend (90:10)
0
Basrah Hy.
8.1
Kuwait
12
Maya
0
Saturno
3.7
1.2
Mangla
Iran mix (75:25)
0
Arab mix (50:50)
0
Forcados
0
Quaiboe
0
Zaffiro
0
Bombay Hi
0
Total Crude
25
The graphical representation of original design crude mix is as follows:
Fig 7.2.3.1: Graphical Representation of the original expansion case
The comparison of key properties and yield pattern for base case and the design case is tabulated below:
Table 7.2.3.2: Design case crude mix comparison with base case
UOM
CCR
wt%
API
Sp. Gravity
Sulfur
wt%
Base Case
Design Case
5.0
7.1
30.6
28.4
0.873
0.885
1.82
2.53
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 13 of 79
UOM
Base Case
Design Case
wt%
1.07
0.80
wt%
5.19
4.79
Yield pattern (TBP °C)
C5
LIGHT NAPHTHA
C5-90°C
HEAVY
NAPHTHA
90°C – 165°C)
wt%
10.92
9.96
165°C – 240°C)
wt%
11.91
10.41
DIESEL (
(240°C – 380°C)
wt%
23.96
22.18
VGO (
380°C – 565°C)
wt%
26.41
24.84
VR
565°C+)
wt%
20.54
27.02
KERO
Following are the observations on the original design crude mix:



Original Design case crude mix is heavier than base case crude mix.
Original Design case crude mix is high sulfur than base case crude mix.
Average price of original design case crude mix is Rs 27132/MT and that for base case crude mix is Rs 28524/MT.
7.2.3.1 Primary Processing Units
The expansion of refinery is aimed at processing 25 MMTPA crude in existing two CDU/ VDUs of capacity 7.5 MMTPA and a new CDU/
VDU of capacity 10 MMTPA. The capacities considered are as follows:
Phase-I CDU/ VDU: 7.5 MMTPA (Design capacity is 7.5 MMTPA)
Phase-II CDU/ VDU: 7.5 MMTPA (Design capacity is 7.5 MMTPA)
Phase-III CDU/ VDU: 10 MMTPA (Design capacity is 10 .0 MMTPA)
In the base case of present study, a blend of 15.0 MMTPA crude is made and 7.5 MMTPA of this blend is routed to CDU-I and 7.5 MMTPA
of this blend is routed to CDU-II. Similarly for expansion cases, a blend of 25.0 MMTPA crude is made and 7.5 MMTPA of this blend is
routed to CDU-I, 7.5 MMTPA of this blend is routed to CDU-II, and balance 10.0 MMTPA of this blend is routed to new CDU.
7.2.3.2 Light Ends Processing
Straight run LPG is considered as feed to existing and new LPG Merox Units. Treated LPG from existing and new process units are
considered for sales. LPG from existing RFCCU, DCU and new Indmax unit are utilized as feed to the new Alkylation unit to maximize
the production of premium gasoline. Fuel gas from existing and new units is the feed to the existing saturated gas plant units, where
sufficient capacity is available.
The existing and new MS block units are utilized for producing regular and premium grade gasoline to meet the market requirements.
7.2.3.3 Secondary Processing Units
As evident from table, existing secondary processing units are saturated in base case corresponding to refinery capacity of 15 MMTPA.
Hence for 25 MMTPA refinery capacity, following new technologies are evaluated for incremental VGO processing:




Full conversion hydrocracker: A full-conversion hydrocracker option is aimed at maximizing middle distillate yield by cracking
entire feed into lighter components, as well as removing sulphur, nitrogen, metals and other contaminants. The products obtained
from hydro-cracker units do not require any further treatment for meeting the finished product specifications. 97wt% conversion is
considered in this unit.
Once through hydrocracker: This option has been studied to maximize propylene yield .In this unit, 55 % conversion is considered
which increases middle distillates from the refinery while also producing low sulfur Indmax feedstock.
Indmax unit: This option has been studied to maximize propylene yield.
VGO Hydrotreater: VGO Hydrotreatment is considered to treat the VGO feed to produce low sulphur Indmax feedstock.
7.2.3.4 Bottom Processing Units
Bottom processing unit are operating at design capacities in Base case corresponding to refinery capacity of 15 MMTPA. Hence for 25
MMTPA refinery capacity, following new technologies are evaluated for incremental VR processing.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 14 of 79
 Solvent Deasphalting Unit
Solvent De-Asphalting (SDA) unit processes vacuum residue. Deasphalted Oil (DAO) extraction rates varying from 30 wt% to 85 wt%
are possible. Vacuum residue is a very difficult feed stock for catalytic processes, whereas DAO can be easily processed like other
heavy distillates. The asphalt produced can be blended with straight run asphalts or blended back with fuel oil. Additionally the asphalt
can be co-processed with VR in the existing DCU unit. SDA units usually use a blend of hydrocarbon solvents (C5-C6 paraffinic cut) to
allow maximum operating flexibility.
In the present study, SDA unit processes incremental vacuum residue from the existing refinery. DAO (30wt% lift) has been considered
to be processed in the new secondary processing unit for VGO, so that feed pools of existing units are not changed. The asphalt has
been considered to be routed to existing and new DCU only. As desired by client, SDA asphalt is not to be considered for bitumen
production.
 Salient Features of Solvent Deasphalting Unit




Low Capital cost and operating cost.
Proven Technology.
Issue of Pitch disposal in case routed to fuel oil pool due to higher cutter stock requirement.
Pitch in case routed to DCU will raise the DCU feed CCR resulting in higher coke make which is a low value product.
 Ebullated Bed Hydrocracker
The Ebullated Bed hydrocracker process is a commercially proven technology for conversion and up gradation of vacuum residue. The
Ebullated Bed hydrocracker process uses the catalytic ebullated-bed reactor. The catalyst used in the ebullated bed reactor is held in a
fluidized state through the upward lift of liquid reactants (feed oil plus recycle) and gas (hydrogen feed and recycle). Catalyst is replaced
periodically in the reactor without shutdown. The typical feed to an ebullated bed plant is vacuum residue with relatively high CCR and
contaminant metals.
The ebullated bed hydrocracker process operates at high severity and utilizes a daily replacement of catalyst to remove contaminant
metals and maintain a constant bulk reactor activity level. This results in the production of constant product quality and yield selectivity.
All the products from the unit require further processing and treatment. Unconverted oil from this unit can be used as fuel oil or
alternatively processed in the existing DCU unit.
There are two most important ebullated bed hydrocracker process (I) LC fining licensed by M/s Chevron and (II) H-OIL licensed by M/s
Axens. Both the processes are similar in concept except the difference in the reactors’ mechanical details. There are more than 12 such
operating units around the world. This unit has been configured as per information (such as feed quality requirement, product yields,
utility requirement etc.) given by respective licensors. As these two cases are based on similar technology, if the information from one of
the licensors is incomplete, it has been supplemented with information from the other licensor.
 Salient Features of Ebullated Bed Hydrocracker
 High distillate yield resulting in good GRM
 Proven Technology
 High Capex and operating cost
 Slurry HCU
Slurry Hydrocracking is designed to convert straight run residual stocks and atmospheric or vacuum residues into distillates by reacting
them with hydrogen in presence of a catalyst. The process operates under severe operating conditions of high temperature and
pressure, comparable to distillate hydrocracker units. A part of the residue is converted into distillates. Also the residue is partially
desulfurized and demetallized. The distillates produced are separated in a distillation column into naphtha, kerosene and light diesel oil.
The heavy products from the reaction section and fractionation tower are separated in a vacuum distillation section into heavy diesel,
heavy vaccum gasoil and pitch. Slurry hydro cracking reaction chemistry is similar to hydroprocessing. The catalyst formulation and the
reactor design are different from conventional hydroprocessing units. Commercial operating reference is not available for this unit,
though extensive pilot plant studies have been done.
 Salient Features of Slurry HCU




Highest distillate yield resulting in high GRM
There is no proven track record for this technology
High capital and operating cost
Issue of disposal of slurry pitch
Slurry Pitch Disposal
Slurry pitch which is residual material from the SHCU is a high energy content pitch having residual iron material and feedstock metals.
Slurry pitch generation is in viscous liquid form which can be solidified and can be converted into the transportable granules. Slurry pitch
can be considered as economical Alternative fuel because of its controlled properties and ease of bulk handling. There are various
value upgrading options for slurry pitch. The options where Slurry pitch can be utilized are as follows:
Solidification of liquid pitch by Belt Conveyor:
Solidification by indirect water cooled conveyor belt followed by simple finger crushing unit.
Solidification of liquid pitch by Extrusion Process of Rutgers:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 15 of 79
A mixture of steam and water, adjusted to a certain temperature, will be added to the liquid pitch - stream in a nozzle, cooling the pitch
down to a moderate solidification temperature.
Cement Industry:
Slurry pitch in the form of solid can be co-fired with coal at up to 30 wt% of the fuel requirement in the cement kilns. Since India has a
large demand for low fuel source for its relatively large Cement industry, this market should be an attractive option for slurry pitch
utilization.
Blast Furnace (BF) Coke Production:
Addition of coal tars as an additive to the coking coal is normal practice for years. Pitch can be such an additive as well with some
positive impacts on coke quality. This addition of pitch to the coking coal blend is proven practice on industrial scale. Hydrogenation
Residue (pitch) is added to coal in solid shape
Foundry Coke Production:
To produce larger pieces of coke with a high carbon content, necessary for cast iron production in the foundry, a binder component is
indispensable for German coal grades. Pitch is a very suitable replacement for expensive binder components used for that purpose.
Pitch is added to the coking coal blend in a solid shape
Circulating Fluid Bed (CFB) Boilers:
There is another option for utilization of slurry pitch as a fuel in CFB boilers. CFB technology has been widely accepted over the last 20
years for high sulphur fuels. CFB boilers have proven ability to handle high sulphur residues and both solid and liquid feeds at wide
variations of throughput. CFB ash contains a mixture of calcium sulphate and oxides and is categorized as a weak cement material and
can be used as soil stabilizer and for civil engineering purposes.
Conventional Combustion in Power Plant:
Like fuel grade petroleum coke solid pitch is fed in a certain percentage to the steam coal for combustion.
Slurry Pitch Gasification:
Slurry pitch similar to other heavy residues may be gasified in partial oxidation (POX) systems with water gas shift of the synthesis gas
with the objective of producing hydrogen in a refinery complex. Gasification of pitch has a relatively high installed cost, but has the
advantage of a continuous non‐ interrupted feedstock at neat zero cost.
Delayed Coking:
Discontinuous Coking Process with VR as feedstock with liquids and petrol coke as product streams. Pitch can be admixed to the
feedstock in a certain percentage. 2 operation modes are applied: anode grade coke, fuel grade coke.
7.2.3.5 Diesel Treating Units
The Diesel Hydrotreating unit processes the diesel cuts to remove sulphur and to meet specification of the Diesel pool. Hydro treatment
of diesel enables production of ultra-low sulphur (8 ppm) diesel, which is required to meet the BS-VI product specifications.
Existing DHDS in PR, DHDT in PREP and BS-VI DHDT units are saturated and a new DHDT and Kero HDS are considered to
process incremental diesel corresponding to 25 MMTPA refinery.
Salient Features of Kero HDS
 Low capital and operating cost
 Low Hydrogen consumption
7.2.3.6 Auxiliary Units
a. HGU
Post saturation of existing HGUs, a new hydrogen generation unit based on naphtha or RLNG as both feed and fuel is been
considered for meeting the additional hydrogen demand. RLNG and naphtha in any proportion can be used as feed to reformer in all
the three existing hydrogen generation unit. PREP HGU 76, 77 can use only naphtha as fuel.
b. Sulfur Block
Additional sour water and sour gas generation due to high sulfur crude under expansion projects warrant incremental sulfur removal
which shall be met by new Sulfuric Acid production unit post saturation of existing SRUs. Owing to no demand of sulphuric acid,
sulphuric acid plant was subsequently changed to SRU.
7.2.3.7 Configuration cases
Based on the above technology options for bottom and secondary processing, following combinations of refinery configurations are
identified for analysis and selection of refinery configuration.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 16 of 79
Table 7.2.3.7.1 - Configuration options analyzed
BOTTOM PROCESSING UNIT
SECONDARY PROCESSING UNIT
FULL CONVERSION HYDROCRACKER
INDMAX (low CCR) + PRU
INDMAX (high CCR) +PRU
DCU
VGOHDT + INDMAX (low CCR) + PRU
OHCU + INDMAX (low CCR) + PRU
OHCU + LOBS
FULL CONVERSION HYDROCRACKER
INDMAX (low CCR) + PRU
INDMAX (high CCR) +PRU
SDA+DCU
VGOHDT + INDMAX (low CCR) + PRU
OHCU + INDMAX (low CCR) + PRU
OHCU + LOBS
FULL CONVERSION HYDROCRACKER
INDMAX (low CCR) + PRU
RESIDUE
HYDROPROCESSING
FACILITY (90% CONVERSION)
INDMAX (high CCR) +PRU
VGOHDT + INDMAX (low CCR) + PRU
OHCU + INDMAX (low CCR) + PRU
OHCU + LOBS
FULL CONVERSION HYDROCRACKER
INDMAX (low CCR) + PRU
RESIDUE HYDROPROCESSING
FACILITY (70% CONVERSION)
INDMAX (high CCR) +PRU
VGOHDT + INDMAX (low CCR) + PRU
OHCU + INDMAX (low CCR) + PRU
OHCU + LOBS
Following configuration cases are considered for the expansion study:
Case AA1: Delayed Coker Unit+ Full Conversion Hydrocracker (LP Case 201)
Case AA2: Delayed Coker Unit + Indmax (high CCR) + PRU (LP Case 241)
Case AA3: Delayed Coker Unit + VGOHDT + Indmax (low CCR) + PRU (LP Case 261)
Case AA4: Delayed Coker Unit+ OHCU + INDMAX (low CCR) + PRU (LP Case 281)
Case AA5: Delayed Coker Unit + OHCU + Indmax ( low CCR) + LOBS (LP Case 292)
Case AA6: Delayed Coker Unit + OHCU + LOBS (LP Case 291)
Case AB1: Solvent De Asphalting + Delayed Coker Unit + Full Conversion Hydrocracker (LP Case 301)
Case AB2 Solvent De Asphalting + Delayed Coker Unit + Indmax (high CCR) + PRU (LP Case 341)
Case AB3: Solvent De Asphalting + Delayed Coker Unit +VGOHDT + Indmax ( low CCR) + PRU LP Case 361)
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 17 of 79
Case AB4: Solvent De Asphalting + Delayed Coker Unit + OHCU + Indmax (low CCR) + PRU (LP Case 381 )
Case AB5: Solvent De Asphalting + Delayed Coker Unit + OHCU + LOBS+ Indmax ( low CCR) + (LP Case 392)
Case AB6: Solvent De Asphalting + Delayed Coker Unit + OHCU + LOBS (LP Case 391)
Case AC1: 90% CONVERSION + Full conversion Hydrocracker (LP Case 401)
Case AC2: 90% CONVERSION + Indmax (high CCR) + PRU (LP Case 441)
Case AC3: 90% CONVERSION + VGOHDT + Indmax ( low CCR) + PRU (LP Case 461
Case AC4: 90% CONVERSION + OHCU + INDMAX (low CCR) + PRU (LP Case 481)
Case AC5: 90% CONVERSION + OHCU + LOBS + Indmax ( low CCR) (LP Case 492)
Case AC6: 90% CONVERSION + OHCU + LOBS (LP Case 491)
Case AD1: 70% CONVERSION + Full Conversion Hydrocracker (LP Case 501)
Case AD2: 70% CONVERSION + Indmax (high CCR) + PRU (LP Case 541)
Case AD3: 70% CONVERSION + VGOHDT + Indmax ( low CCR) + PRU (LP Case 561)
Case AD4: 70% CONVERSION + OHCU + INDMAX (low CCR) + PRU (LP Case 581)
Case AD5: 70% CONVERSION + OHCU + LOBS + Indmax ( low CCR) (LP Case 592)
Case AD6: 70% CONVERSION + OHCU + LOBS (LP Case 591)
The production of LOBS grade-II and grade-III were capped at 500 KTPA maximum. OHCU bottoms only can be utilized as feed to the LOBS
unit. So, either a small secondary processing unit to process the balance OHCU bottoms was to be considered or the production limit of LOBS
had to be increased. A low CCR Indmax unit along with PRU is considered for balance OHCU bottoms processing.
Hence, cases AA6, case AB6, case AC6 and case AD6 were eliminated as OHCU bottoms only can be utilized as feed to the LOBS unit.
Cases AA5, AB5, AC5 and AD5 with Indmax (low CCR) were considered for the configuration study.
It was observed that SDA unit requires more hydrogen, so LP model prefers to process the vacuum residues directly in bottom processing
units: DCU, Ebulated bed and slurry hydrocracker rather than having a 30wt% lift upstream of these bottom processing units. Based on
economics, SDA unit is found to be not feasible.
7.2.4
Preliminary results for configuration screening
The section here summarises the results obtained for each of the above configuration options. Total 20 configuration cases were studied for
this expansion. Out of 20 cases, options with SDA were eliminated due to economics.
7.2.4.1 Material Balance
Material balance for the 15 cases is tabulated below.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 18 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Crude Blend
25000.0
25000.0
25000.0
25000.0
25000.0
25000.0
25000.0
25000.0
25000.0
25000.0
25000.0
25000.0
Case
AD3
25000.0
LNG
1901.7
1677.3
1772.0
1810.3
1793.4
1865.9
1738.2
1853.9
1935.0
1897.9
1697.9
2074.5
C7-C8 from PNCP
C9+ stream from PNCP
228.0
228.0
228.0
228.0
228.0
228.0
228.0
228.0
228.0
228.0
228.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
Fuel oil from PNCP
112.0
112.0
112.0
112.0
112.0
112.0
112.0
112.0
112.0
C4 from PNCP
C5 from PNCP
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
170.0
170.0
170.0
170.0
170.0
170.0
170.0
6.8
6.8
6.8
6.8
6.8
6.8
Mathura Ref. Naphtha
150.0
150.0
150.0
150.0
150.0
Air for PTA
MethanoL TO TAME
Unit
Additive FOR 90% con.
Additive FOR 70% con.
Catalyst Make up for
indmax
TOTAL
239.5
239.5
239.5
239.5
11.4
11.4
11.4
0.0
0.0
0.0
0.0
0.0
28119
70%CONVERSIO
N+OHCU+INDMA
X (LOW
CCR)+LOBS
+PRU
Case AD1
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
70%CONVERS
ION+VGOHDT
+INDMAX LOW
CCR+PRU
70%
CONVERSION
+OHCU+INDM
AX LOW
CCR+PRU
Case AC5
70%
CONV+INDMA
X HIGH
CCR+PRU
Case
AC4
70%
CONV+FCHCU
Case AC3
90%CONVERS
ION+OHCU+IN
DMAX (LOW
CCR)+LOBS
90%CONVERS
ION+VGOHDT
+INDMAX LOW
CCR+PRU
Case AC2
90%
CONVERSION
+OHCU+INDM
AX LOW
CCR+PRU
90%
CONV+INDMA
X HIGH
CCR+PRU
Case AC1
90%
CONV+FCHCU
Case AA5
DCU+OHCU+I
NDMAX (LOW
CCR)+LOBS
Case AA4
DCU+OHCU+I
NDMAX LOW
CCR+PRU
Case AA3
DCU+INDMAX
HIGH
CCR+PRU
Case
AA2
DCU+FCHCU
Case
AA1
Surplus H2 available
DCU+VGOHDT
+INDMAX LOW
CCR+PRU
Table 7.2.4.1.1 Feedstock purchases (KTPA)
25000.0
Case
AD5
25000.0
2084.7
1856.3
1757.9
228.0
228.0
228.0
228.0
100.0
100.0
100.0
100.0
100.0
112.0
112.0
112.0
112.0
112.0
112.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
170.0
170.0
170.0
170.0
170.0
170.0
170.0
170.0
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
150.0
150.0
150.0
150.0
150.0
150.0
150.0
150.0
150.0
150.0
239.5
239.5
239.5
239.5
239.5
239.5
239.5
239.5
239.5
239.5
239.5
11.4
11.0
9.6
9.6
9.6
9.6
9.6
9.6
9.6
9.6
9.6
9.6
0.0
0.0
0.0
0.0
0.0
0.0
6.4
0.0
5.4
0.0
6.4
0.0
6.4
0.0
6.5
0.0
0.0
2.5
0.0
2.4
0.0
2.7
0.0
2.6
0.0
2.6
7.4
1.7
0.8
0.4
0.0
8.2
1.8
1.2
0.8
0.0
10.1
1.7
0.8
0.4
27902
27991
28029
28011
28088
27968
28078
28159
28121
27916
28303
28305
28076
27977
Case AD2
Case AD4
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 19 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
70%
CONVERSIO
N+OHCU+IN
DMAX LOW
CCR+PRU
Case AC3
Case AC4
Case AC5
Case AD1
Fuel gas
from
existing
refinery
90
88.7
88.7
88.7
88
82
82
82
82
82
Fuel gas
from PR
expn
16.5
100
97.9
57.1
36.8
0
130.4
90.2
62.4
Propylene
from
existing
refinery
107.9
107.9
107.9
107.9
105.2
90.4
90.4
90.4
Propylene
from PR
expn
56
521.5
530.3
281.5
167.7
20.3
652.5
Mixed
LPG'S
883
1298.1
1350
1082.8
939.4
1101.8
Total
naphtha to
PNCP
2381.8
2315.3
1746
1746
1812.9
PX stream
to sales at
nap price
0
36.8
0
0
BS-VI reg.
gasoline
3410.8
3794.1
4213.7
Benzene
24.6
24.6
PTA
700
ATF
BS-VI
HSD
HIgh
sul.f.oil
90% conv.
pitch
70%CONVERSI
ON+OHCU+IND
MAX (LOW
CCR)+LOBS
+PRU
70%CONVER
SION+VGOH
DT+INDMAX
LOW
CCR+PRU
Case AC2
Case AD2
Case AD3
Case AD4
Case AD5
89.8
84.8
86.2
88.7
88.7
39.2
0
133.6
85.3
41.1
19.5
90.4
90.4
92.4
90.4
91.1
92.4
92.4
540.3
367
238.3
20.3
636.7
518
248.6
128.4
1656.1
1615.5
1435.5
1280.2
955.1
1535.1
1454.2
1155.9
1012
2225.9
1912.1
1746
1746
1746
2127.2
2082.7
1746
1746
1746
0
0
53.5
0
0
0
0
57.8
0
0
0
4121.7
3869.2
3407.9
4103.2
4202
4157
3937
3734.8
4315.4
4402.9
4295.8
4114.6
24.6
24.6
24.6
24.6
24.6
24.6
24.6
24.6
24.6
24.6
24.6
24.6
24.6
700
700
700
700
700
700
700
700
700
700
700
700
700
700
1300
1300
1300
1300
1300
1300
1300
1300
1300
1300
1300
1300
1300
1300
1300
13906.
1
12111.1
12320.2
13163.3
13181.2
14354.5
12218.5
12637
13248.9
13303.9
14391.1
12678.1
13091.4
13748.8
13681
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
288.8
235.4
288.9
289.6
288.2
0
0
0
0
0
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
70%
CONV+INDM
AX HIGH
CCR+PRU
90%CONVER
SION+OHCU
+INDMAX
(LOW
CCR)+LOBS
Case
AC1
70%
CONV+FCHC
U
90%
CONVERSIO
N+OHCU+IN
DMAX LOW
CCR+PRU
Case
AA5
90%
CONV+INDM
AX HIGH
CCR+PRU
Case
AA4
90%
CONV+FCHC
U
Case
AA3
DCU+OHCU+
INDMAX
(LOW
CCR)+LOBS
Case
AA2
DCU+INDMA
X HIGH
CCR+PRU
Case
AA1
DCU+FCHCU
90%CONVER
SION+VGOH
DT+INDMAX
LOW
CCR+PRU
DCU+OHCU+
INDMAX LOW
CCR+PRU
DCU+VGOHD
T+INDMAX
LOW
CCR+PRU
Table 7.2.4.1.2: Product Sales (KTPA)
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 20 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Bitumen
360
360
360
360
360
499
499
499
499
499
499
360
499
499
499
Coke
2092.5
2092.5
2092.5
2092.5
2092.5
867
867
867
867
867
912.6
867
883.5
912.6
912.6
316.4
316.6
369.8
324.4
315
435.5
415.1
495.7
464.9
454.6
404.7
407.7
499.6
440.6
429.3
0
0
0
0
144.7
0
0
0
0
144.7
0
0
0
0
144.7
0
0
0
0
78.9
0
0
0
0
78.9
0
0
0
0
78.9
0
0
0
0
125
0
0
0
0
125
0
0
0
0
125
0
0
0
0
50
0
0
0
0
50
0
0
0
0
50
Lube
grade II
500n
0
0
0
0
101.4
0
0
0
0
101.4
0
0
0
0
101.4
Ref. total
losses
2473.8
2735.4
2689.9
2578.4
2518.5
2690.5
3028
2899.4
2824.2
2770.4
2664.5
3029
2923.2
2781.6
2728.9
Total
28119
27902.6
27991.5
28028.9
28011
28088.2
27967.8
28078
28158.5
28120.8
27916.1
28302.9
28305
28075.7
27977
Product
sulphur
Lube
grade II
150N
Lube
grade III
3cst
Lube
grade III
6cst
Lube
grade III
8cst
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Case AA3
Case AA4
Case AC2
Case AC3
Case AC4
Case AC5
Case AD2
Case AD3
Case AD4
DCU+VGOHDT+INDMA
X LOW CCR+PRU
DCU+OHCU+INDMAX
LOW CCR + PRU
DCU+OHCU+INDMAX
LOW CCR + LOBS
90% CONV+FCHCU
90% CONV+INDMAX
HIGH CCR+PRU
90%CONVERSION+VG
OHDT+INDMAX LOW
CCR+PRU
90%
CONVERSION+OHCU+I
NDMAX LOW
CCR+PRU
90%CONVERSION+OH
CU+INDMAX LOW CCR
+LOBS
70% CONV+FCHCU
70% CONV+INDMAX
HIGH CCR+PRU
70%CONVERSION+VG
OHDT+INDMAX LOW
CCR+PRU
70%
CONVERSION+OHCU+I
NDMAX LOW
CCR+PRU
93.1
80.1
97.8
100.9
145.7
124.7
121.7
134.6
138.5
141.4
132.4
122.3
138.7
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
70%CONVERSION+OHCU
+INDMAX LOW CCR
+LOBS
+PRU
Case AA2
DCU+INDMAX HIGH
CCR+PRU
102.7
Case AD5
Case AD1
Case AC1
Case AA5
Case AA1
POWER
IMPORT
(MW)
DCU+FCHCU
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 21 of 79
7.2.4.2 Power import
Table 7.2.4.2.1 Power import- All cases
142.3
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 22 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.2.4.3 Unit Capacity Utilization
The unit capacities in KTPA for all the cases have been established after utilizing the available margins in the existing units. The capacities of the new units are tabulated below.
Case AA4
Case AA5
Case AC1
Case AC2
Case AC3
Case AC4
Case AC5
Case AD1
Case AD2
Case AD3
Case AD4
DCU+OHCU+IND
MAX LOW CCR +
PRU
DCU+OHCU+IND
MAX LOW CCR +
LOBS
90%
CONV+FCHCU
90%
CONV+INDMAX
HIGH CCR+PRU
90%CONVERSIO
N+VGOHDT+IND
MAX LOW
CCR+PRU
90%
CONVERSION+O
HCU+INDMAX
LOW CCR+PRU
90%CONVERSIO
N+OHCU+INDMA
X LOW CCR
+LOBS
70%
CONV+FCHCU
70%
CONV+INDMAX
HIGH CCR+PRU
70%CONVERSIO
N+VGOHDT+IND
MAX LOW
CCR+PRU
70%
CONVERSION+O
HCU+INDMAX
LOW CCR+PRU
10000.0
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
FC
HYDROCRACER
3109.2
0.0
0.0
0.0
0.0
3147.9
0.0
0.0
0.0
0.0
3166.3
0.0
0.0
0.0
0.0
DELAYED COKER
3874.8
3874.8
3874.8
3874.8
3874.8
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
VGO
HYDROTREATER
0.0
0.0
2685.8
0.0
0.0
0.0
0.0
1921.3
0.0
0.0
0.0
0.0
2979.6
0.0
0.0
OHCU
0.0
0.0
0.0
2754.8
2744.1
0.0
0.0
0.0
2136.3
2196.2
0.0
0.0
0.0
3063.5
2970.3
ETHYLENE
RECOVERY
165.5
192.1
321.7
243.4
204.4
0.0
250.3
173.2
119.8
75.3
0.0
256.5
163.7
78.9
37.3
DIESEL
HYDROTREATER
3940.0
4678.2
4099.9
3941.7
3932.4
2381.8
3248.7
2702.1
2546.5
2494.5
4279.8
5156.0
4706.6
4418.4
4454.7
PROPYLENE
RECOV
35.6
1019.8
1065.3
533.8
284.7
0.0
1336.5
1128.7
765.7
481.4
0.0
1303.2
1080.4
504.1
238.7
90%CONV. UNIT
0.0
0.0
0.0
0.0
0.0
3601.1
2934.7
3602.3
3611.3
3594.0
0.0
0.0
0.0
0.0
0.0
70% CONV. UNIT
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
5069.3
4882.7
5479.5
5173.5
5119.9
INDMAX
0.0
3007.2
2306.6
1094.9
547.4
0.0
3849.7
2512.0
1682.9
1058.1
0.0
4029.7
2423.0
1108.0
524.6
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Case AD5
Case AA3
DCU+VGOHDT+I
NDMAX LOW
CCR+PRU
CRUDE UNIT #3
70%CONVERSION+
OHCU+INDMAX
LOW CCR +LOBS
+PRU
Case AA2
DCU+INDMAX
HIGH CCR+PRU
Case AA1
DCU+FCHCU
Table 7.2.4.3.1 Capacity utilization of new units (KTPA)
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 23 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
FPU FOR LOBS
0.0
0.0
0.0
0.0
580.4
0.0
0.0
0.0
0.0
580.4
0.0
0.0
0.0
0.0
580.4
CIDW FOR LOBS
0.0
0.0
0.0
0.0
533.6
0.0
0.0
0.0
0.0
533.6
0.0
0.0
0.0
0.0
533.6
NHT FOR CCR
490.6
501.8
540.3
747.1
746.1
538.5
540.8
577.3
737.5
742.8
742.5
733.6
796.5
1021.5
1018.0
CCR
489.6
500.7
539.3
745.6
744.6
537.4
539.7
576.1
736.0
741.4
741.0
732.1
794.9
1019.4
1015.9
NHT FOR ISOM
1114.2
723.6
915.5
981.5
959.7
1095.9
859.0
802.4
839.2
865.3
1057.3
853.7
772.6
823.6
900.5
ISOM
1095.8
711.7
900.4
965.3
943.8
1077.8
844.8
789.2
825.4
851.1
1039.8
839.7
759.8
810.0
885.6
FGDS
0.0
557.3
0.0
0.0
0.0
0.0
755.3
0.0
0.0
0.0
0.0
738.3
0.0
0.0
0.0
CHT
0.0
318.7
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
VHP STEAM
BOILER (TPH)
35.2
70.8
315.3
153.6
94.4
0.0
141.3
293.4
181.9
114.4
0.0
84.5
295.8
119.8
56.7
HP STEAM BOILER
(TPH)
445.6
766.8
396.1
453.0
471.8
347.9
678.8
291.5
336.1
364.8
306.6
704.3
265.2
300.4
323.4
NEW HGU
44.5
0.0
0.0
16.3
15.7
137.7
62.1
93.1
105.5
105.8
130.3
69.2
100.8
113.3
113.5
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 24 of 79
Refinery Configuration Study
Feasibility study for capacity expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.2.4.4 Gross refinery margin
The Gross refining margin in Rupees Crore/ annum and $/bbl for the refinery configurations is tabulated below along with total project cost and simple payback period.The refining margins indicated are based on 3
year average crude and product prices.
Case AC4
Case AC5
Case AD2
Case AD3
Case AD4
90%
CONVERSION+
OHCU+INDMAX
LOW CCR+PRU
90%CONVERSI
ON+OHCU+IND
MAX LOW CCR
+LOBS
70%
CONV+FCHCU
70%
CONV+INDMAX
HIGH CCR+PRU
70%CONVERSI
ON+VGOHDT+I
NDMAX LOW
CCR+PRU
70%
CONVERSION+
OHCU+INDMAX
LOW CCR+PRU
70%CONVERSION
+OHCU+INDMAX Case AD5
LOW CCR +LOBS
+PRU
Case AC3
90%CONVERSI
ON+VGOHDT+I
NDMAX LOW
CCR+PRU
Case AD1
Case AC2
90%
CONV+INDMAX
HIGH CCR+PRU
Case AC1
90%
CONV+FCHCU
Case AA5
DCU+OHCU+IN
DMAX LOW
CCR + LOBS
Case AA4
DCU+OHCU+IN
DMAX LOW
CCR + PRU
GRM (RS
CR/A)
12113.9
11391.8
12241.2
12594.3
12968.5
13175.8
13022.1
13327.5
13604.6
14000.9
14779.4
14533.4
14844.7
15062.3
15439.3
GRM
(US$/BBL)
10.0
9.4
10.1
10.4
10.7
10.9
10.8
11.0
11.3
11.6
12.2
12.0
12.3
12.5
12.8
TOTAL
PROJECT
COST (RS
CR)
20239
24344
25589
24160
24660
26242
32759
33522
32550
33090
26517
34652
35188
32213
32395
SIMPLE
PAYBACK
(YEARS)
3.0
4.1
3.8
3.4
3.3
3.4
4.3
4.3
4.0
3.9
2.8
3.8
3.8
3.4
3.2
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Case AA3
DCU+VGOHDT+
INDMAX LOW
CCR+PRU
Case AA2
DCU+INDMAX
HIGH CCR+PRU
Case AA1
DCU+FCHCU
Table 7.2.4.4.1 Gross Refinery Margin, Total Project cost and simple payback period
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 25 of 79
7.2.4.5 Observations and Inferences
Based on the results presented in the section above, following points are noted:

No limit on RLNG import is to be considered. Also, internal fuel oil made open based
on economics.

CCR in existing DCU is to be maintained at 25 wt%.

Cracked feed to OHCU and HCU is maintained within 20wt% of total feed to
maintain nitrogen limit in the feed.

Slop from VDUs is not routed to existing HCU’s because of limitation on arsenic and
other metals in feed to these units.
 DCU light naphtha is routed to new splitter in revamped Prime G unit, and DCU
heavy naphtha is routed to DHDT unit.
 OHCU heavy naphtha may be routed to CCR. Full conversion HCU heavy naphtha is
to be routed to diesel.

OHCU/ FC-HCU light naphtha is not be routed to ISOM.
 Minimum density specification for BS-VI Diesel is to be removed in line with latest
BS-VI gazette notification from govt.
 HGU’s (existing and new) can be operated on naphtha or RLNG feed, whichever is
economical. RLNG and naphtha in any proportion can be used as feed to reformer in all
three hydrogen generation unit. HGU 76, 77 can use only naphtha as fuel.

All GT’s to be operated only on RLNG feed.
 Since the price of RLNG provided is high, eliminating internal fuel oil (max sulphur of
0.5 wt. %) will lead to drop in GRM for expansion cases. Hence replacement of entire
refinery fuel to refinery fuel gas and RLNG is not be considered.
 Prices considered are based on 3 year Average price (1st April2014-31st March
2017).
 Internal Fuel oil make in expansion cases is based on economics (based on price of
RLNG).
 Separate new Kero HDS has not been considered in order to restrict cracked feed %
to new DHDT unit
 IOCL informed that in absence of any demand of H2SO4 in Panipat region, EIL to
consider production of sulfur in all expansion cases.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 26 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Based on simple payback, EIL recommended following two cases for shortlisting:
•
LP CASE AA1 : DCU+FCHCU
•
LP CASE AD1 : 70% CONV+FCHCU
Moreover, EIL suggested that if investment cost is not limiting then LP Case AD5:
70%CONVERSION+OHCU+INDMAX (LOW CCR) + LOBS, with marginally higher
simple payback but highest GRM appear promising.
However, Case AA1 was not considered because IOCL raised concerns about handling
of additional coke with the installation of a new Delayed Coker Unit. It was decided that a
new DCU as bottom processing unit will not be considered for this study.
Case AD1 was not considered because there was no petrochemical potential in this
configuration case.
IOCL suggested the following:

PPU along with PRU to be considered in expansion cases to boost GRM.
 For OHCU+LOBS cases (Cases AA5, AC5 and AD5) the capacity of LOBS unit was
capped at 500KTPA. Only OHCU bottoms are used as feed to LOBS unit. In order to
accommodate remaining OHCU bottoms an Indmax unit was considered. But the
capacity of Indmax unit was very small, which was uneconomical, hence the capacity of
LOBS unit was increased from 500 to 1000 KTPA.

OHCU revamp to 2.4 MMTPA capacity with 4 drum system to be considered.

Continuous catalyst make up for bottom hydro processing unit (70% conversion) and
Indmax unit to be considered in OPEX.

Catalyst/additive make up for bottom hydro processing unit (90% conversion) lands
up in pitch. Hence, this catalyst/ additive make up to be considered in GRM.
7.2.5 New Configuration Cases
Based on the above observations, configuration study shall be done on 10 cases with 5
secondary processing options and 2 bottom processing options of 90% and 70% bottom
hydro processing units. Results and analysis for ten LP cases are as follows:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 27 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.5.1: Feedstock purchases (KTPA) for cases with PPU
CASE
AP1
90%
CONV+F
CHCU
crude blend
LNG
C7-C8 from
PNCP
C9+ from
PNCP
Fuel oil from
PNCP
C4 from PNCP
C5 from PNCP
Surplus h2
available
Mathura ref.
naphtha
Air for PTA
Methanol to
tame unit
Additive for
90% conv. unit
25000
1865.7
CASE AP2
CASE AP3
CASE AP4
90%CONV
90%
90%
ERSION+V CONVERSI
CONV+IND GOHDT+IN ON+OHCU
MAX HIGH
DMAX
+INDMAX
CCR+PRU
LOW
LOW
+PPU
CCR+PRU+ CCR+PRU+
PPU
PPU
25000
25000
25000
1739.3
1859.2
1944.1
CASE AP5
CASE BP1
CASE BP2
90%CONV
ERSION+O
HCU+INDM
AX (LOW
CCR)+LOB
S+PPU
70%
CONV+FCH
CU
70%
CONV+IN
DMAX
HIGH
CCR+PRU
+PPU
25000
1962.9
25000
1699
25000
2067.7
CASE BP3
CASE BP4
70%CONV
70%
ERSION+V CONVERSI
GOHDT+IN ON+OHCU
DMAX
+INDMAX
LOW
LOW
CCR+PRU+ CCR+PRU+
PPU
PPU
25000
25000
2086.6
1859.2
CASE BP5
70%CONV
ERSION+O
HCU+INDM
AX (LOW
CCR)+LOB
S+PPU
25000
1812.3
228
228
228
228
228
228
228
228
228
228
100
100
100
100
100
100
100
100
100
100
112
112
112
112
112
112
112
112
112
112
200
170
200
170
200
170
200
170
200
170
200
170
200
170
200
170
200
170
200
170
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
150
150
150
150
150
150
150
150
150
150
239.5
239.5
239.5
239.5
239.5
239.5
239.5
239.5
239.5
239.5
9.6
9.6
9.6
9.6
9.6
9.6
9.6
9.5
9.6
9.6
6.4
5.4
6.7
6.7
6.8
0
0
0
0
0
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 28 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.5.2: Product Sales (KTPA) for cases with PPU
Fuel gas
from PR
expn
Lube grade
II 150n
Lube grade
IIi 3cst
Lube grade
III 6cst
Lube grade
III 8cst
Lube grade
II 500n
Mixed
LPG'S
Propylene
from
CASE AP1
CASE AP2
CASE AP3
CASE AP4
CASE AP5
CASE BP1
CASE BP2
CASE BP3
CASE BP4
CASE BP5
90%
CONV+FCH
CU
90%
CONV+IND
MAX HIGH
CCR+PRU+
PPU
90%CONVE
RSION+VG
OHDT+IND
MAX LOW
CCR+PRU+
PPU
90%
CONVERSI
ON+OHCU+
INDMAX
LOW
CCR+PRU+
PPU
90%CONVE
RSION+OH
CU+INDMA
X (LOW
CCR)+LOB
S+PPU
70%
CONV+FCH
CU
70%
CONV+IND
MAX HIGH
CCR+PRU
+PPU
70%CONVE
RSION+VG
OHDT+IND
MAX LOW
CCR+PRU+
PPU
70%
CONVERSI
ON+OHCU+
INDMAX
LOW
CCR+PRU+
PPU
70%CONVE
RSION+OH
CU+INDMA
X (LOW
CCR)+LOB
S+PPU
0
138.7
95.4
63.5
53.8
0
141.5
89.2
41.1
31.1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
36.6
0
0
0
0
36.6
0
0
0
0
125
0
0
0
0
125
0
0
0
0
50
0
0
0
0
50
0
0
0
0
20.1
0
0
0
0
20.1
1101.8
1700.3
1658.1
1453.3
1390.8
955.2
1565.6
1477.6
1155.9
1089.1
110.7
79.4
79.4
79.4
79.4
112.7
79.4
79.5
80.4
80.4
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 29 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
existing
refinery
Poly
propylene
Naphtha
Stream to
MS pool
Fuel gas
from
existing
refinery
BS-VI reg
gasoline
Benzene
PTA
Total
naphtha to
PNCP
ATF
BS-VI HSD
0
693.8
576.8
380.7
327.1
0
675.1
547.6
258.2
203
0
61.6
0
0
0
0
65.8
0
0
0
82
82
82
82
84.8
89.8
84.8
88.4
88.7
88.7
3407.3
4116.5
4232.6
4170.2
4075.6
3735
4318
4421.7
4295.9
4211.6
24.6
700
24.6
700
24.6
700
24.6
700
24.6
700
24.6
700
24.6
700
24.6
700
24.6
700
24.6
700
2226.3
1938.3
1746
1746
1746
2127.3
2108
1746
1746
1746
1300
14354.5
1300
12163.7
1300
12615.1
1300
13314.5
1300
13343.9
1300
14392.3
1300
12543.1
1300
13083.7
1300
13750.4
1300
13719.6
High sul.f.oil
0
0
0
0
0
0
0
0
0
0
BHU pitch
Bitumen
288.8
499
244.1
360
299.9
360
300.8
360
303.3
360
0
499
0
360
0
382.7
0
499
0
499
Coke
Product
sulphur
867
867
867
867
867
912.6
867
912.6
912.6
912.6
435.5
420.7
508.2
473.5
466.6
404.7
405
506
440.6
435.3
2690.6
3070.1
2936.7
2851.2
2830.9
2662
3045.7
2942.9
2782
2755.8
Ref. total
losses
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 30 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.5.3: Capacity of new units (KTPA)
CASE
AP1
CASE AP2
CASE AP3
CASE AP4
CASE AP5
CASE
BP1
CASE BP2
CASE BP3
CASE BP4
CASE BP5
90%
CONV+FC
HCU
90%
CONV+IN
DMAX
HIGH
CCR+PRU
+PPU
90%CONV
ERSION+V
GOHDT+I
NDMAX
LOW
CCR+PRU
+PPU
90%
CONVERS
ION+OHC
U+INDMA
X LOW
CCR+PRU
+PPU
90%CONV
ERSION+
OHCU+IN
DMAX
(LOW
CCR)+LO
BS+PPU
70%
CONV+FC
HCU
70%
CONV+IN
DMAX
HIGH
CCR+PRU
+PPU
70%CONVE
RSION+VGO
HDT+INDMA
X LOW
CCR+PRU+
PPU
70%
CONVERSION
+OHCU+INDM
AX LOW
CCR+PRU+PP
U
70%CONVERS
ION+OHCU+IN
DMAX (LOW
CCR)+LOBS+P
PU
CDU/VDU
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
FHCU
3147.9
0
0
0
0
3166.4
0
0
0
0
VGO HDT
0
0
2136.3
0
0
0
0
3128.3
0
0
OHCU
0
0
0
2136.3
2136.3
0
0
0
3063.6
2989.9
ERU
0
266.2
183.2
121.9
103.3
0
271.6
171.2
78.9
59.6
DHDT
2381.8
3317.4
2726.4
2549.8
2527.3
4280
5194.6
4766.4
4418.7
4409.5
PSU
SRU
0
266.5
1424.8
250.1
1206.4
339.1
790.2
304.4
670.9
301.9
0
236.9
1385.1
238.8
1142.1
338.6
516.2
273.4
393.1
266.6
90%conv.
unit
3601.1
3043.4
3739.7
3750.3
3782.1
0
0
0
0
0
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 31 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
70% conv.
unit
0
0
0
0
0
5069.9
4797.7
5514.3
5174.3
5149.4
INDMAX
0
4104.3
2662.1
1712.5
1450.3
0
4274.4
2534.5
1108
837.7
0
0
0
0
269
0
0
0
0
269
0
0
0
0
247.3
0
0
0
0
247.3
538.5
531.1
571
739.3
739.8
742.5
718.4
797.4
1021.5
1019.9
537.4
530
569.9
737.9
738.3
741
717
795.8
1019.5
1017.8
1096.6
837.7
784.3
838.1
849.1
1057.3
831.7
749.5
824.3
855
1078.5
0
823.8
799.1
771.3
0
824.3
0
835.1
0
1039.8
0
817.9
778.6
737.2
0
810.7
0
840.9
0
0
143.3
312.1
185.1
156.8
0
84.1
309.6
119.8
90.6
347.9
720.8
292.7
343.7
359.2
306.6
704.3
265.2
300.4
323.4
137.7
0
62.3
693.8
95.8
576.8
110.3
380.7
111.2
327.1
130.3
0
64.4
675.1
100.9
547.6
113.4
258.2
113.1
203
FPU for
lobs
CIDW for
lobs
NHT for
CCR
CCR
NHT for
ISOM
ISOM
FGDS
VHP steam
boiler TPH
HP steam
boiler TPH
HGU
PPU
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 32 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.5.4: Power import for the cases with PPU
POWER
IMPORT
CASE
AP1
CASE
AP2
CASE
AP3
CASE
AP4
CASE
AP5
90%
CONV+F
CHCU
90%
CONV+IN
DMAX
HIGH
CCR+PRU
+PPU
90%CON
VERSION
+VGOHD
T+INDMA
X LOW
CCR+PR
U++PPU
90%
CONVER
SION+OH
CU+INDM
AX LOW
CCR+PR
U+PPU
145.7
158.1
148.7
154.1
Template No. 5-0000-0001-T2 Rev. 1
CASE
BP1
CASE
BP2
CASE
BP3
CASE
BP4
CASE
BP5
90%CON
VERSION
+OHCU+I
NDMAX
(LOW
CCR)+LO
BS+PPU
70%
CONV+FC
HCU
70%
CONV+IN
DMAX
HIGH
CCR+PR
U+PPU
70%CON
VERSION
+VGOHD
T+INDMA
X LOW
CCR+PR
U+PPU
70%
CONVER
SION+OH
CU+INDM
AX LOW
CCR+PR
U+PPU
70%CON
VERSION
+OHCU+I
NDMAX
(LOW
CCR)+LO
BS+PPU
153.4
141.4
162
147
150.5
149.5
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 33 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.5.5: GRM. Total project cost Simple payback
CASE
AP1
CASE
AP2
CASE
AP3
CASE
AP4
CASE
AP5
90%
CONV+F
CHCU
90%
CONV+IN
DMAX
HIGH
CCR+PRU
+PPU
90%CON
VERSION
+VGOHD
T+INDMA
X LOW
CCR+PR
U++PPU
90%
CONVER
SION+OH
CU+INDM
AX LOW
CCR+PR
U+PPU
GRM (RS
CR/A)
13174.8
15714.2
15407.8
GRM
(US$/BBL)
10.9
13
TOTAL
PROJECT
COST (RS
CR)
22322.5
SIMPLE
PAYBACK
(YEARS)
2.9
Template No. 5-0000-0001-T2 Rev. 1
CASE
BP1
CASE
BP2
CASE
BP3
CASE
BP4
CASE
BP5
90%CON
VERSION
+OHCU+I
NDMAX
(LOW
CCR)+LO
BS+PPU
70%
CONV+FC
HCU
70%
CONV+IN
DMAX
HIGH
CCR+PR
U+PPU
70%CON
VERSION
+VGOHD
T+INDMA
X LOW
CCR+PR
U+PPU
70%
CONVER
SION+OH
CU+INDM
AX LOW
CCR+PR
U+PPU
70%CON
VERSION
+OHCU+I
NDMAX
(LOW
CCR)+LO
BS+PPU
14989.5
14998.1
14948.4
17356.8
16996
16168.6
16167
12.7
12.4
12.4
12.4
14.4
14.1
13.4
13.4
27578.3
28152.6
27257.1
28226.3
22677.5
28848.3
29364.2
26979
27615.1
2.7
2.8
2.9
3
2.4
2.4
2.5
2.5
2.6
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 34 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.5.6 Observations
 However, it was observed that the total project cost for these cases was very high. A
decision was reached to change the design crude mix. New design crude mix considered
will be same as Base Case crude mix except for substitution of 0.5 MMTPA of Mangla
crude with equivalent quantity of Dalia crude. This revised crude mix is low in sulphur
and lighter. However, objective for optimization for expansion case shall be same as
considered for earlier design case crude mix.
 IOCL informed that ethylene recovery from new units shall not be considered. IOCL
confirmed that the ethylene rich fuel gas is to be considered as fuel to expanded refinery
and shall not be considered as export to PNCP for ethylene recovery.

Owing to low hydrogen demand Kero HDS unit to be considered.
 ATF production limit to be considered as 1500 KTPA (in place of 1300 considered
earlier).
 LOBS production limit to be considered as1000 KTPA (in place of 500 KTPA
considered earlier). So, Indmax unit shall be eliminated from the LP cases AP5 and BP5.
7.2.7 New Design Crude Mix
The new design crude mix considered is same as that of base case crude mix except for
substitution of 0.5 MMTPA of Mangla crude with equivalent quantity of Dalia crude
Table 7.2.7.1: New Design Crude Mix
Base Case
[MMTPA]
(SAME AS BS-VI
STUDY)
Original Design
Crude Mix
Bonny Lt.
1
0
1.7
Basrah blend (90:10)
4
0
6.7
Basrah Hy.
0
8.1
0
Kuwait
3.25
12
5.4
Maya
0.75
0
1.3
Saturno
0
3.7
0
Mangla
1
1.2
1.2
Dalia
0
0
0.5
Crudes
Template No. 5-0000-0001-T2 Rev. 1
(MMTPA)
New Design Crude
Mix (MMTPA)
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 35 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Iran mix (75:25)
1
0
1.7
Arab mix (50:50)
1.25
0
2.1
Forcados
0.5
0
0.8
Escravos
0.5
0
0.8
Quaiboe
0.75
0
1.3
Zaffiro
0.5
0
0.8
Bombay Hi
0.5
0
0.8
Total
15
25
25
Graphical representation of new design crude mix:
Fig 7.2.7.1: New design crude mix
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 36 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Crude mix comparison between original and new design crude mix is as follows:
Table 7.2.7.2: Crude mix comparison
Yield difference
between new and
original design case
crude mix
Crudes
Base Case
Original
Design
Crude Mix
Specific gravity
API
Sulfur (wt%)
CCR (wt%)
Yields (wt%)
C5LIGHT NAPHTHA (C590°C)
HEAVY NAPHTHA (90°C
– 165°C)
KERO (165°C – 240°C)
DIESEL (240°C – 380°C)
VGO (380°C – 565°C)
VR (565°C+)
0.873
30.6
1.82
5
0.885
28.4
2.53
7.1
0.873
30.6
1.82
5
1.07
0.8
1.07
0.27
5.19
4.79
5.19
0.4
10.92
11.91
23.96
26.41
20.54
100
9.96
10.41
22.18
24.84
27.02
100
10.92
11.91
23.96
26.41
20.54
100
0.96
1.49
1.78
1.57
-6.48
New Design
Crude Mix
Following points are noted:
•
New design case crude mix is lighter than original design case crude mix.
•
New design case crude mix is low sulfur than original design case crude mix.
•
Average price of new design case crude mix is Rs 28524/MT and that for original design case crude mix is
Rs 27132/MT.
•
Hence, new design case crude mix is expensive than original design case crude mix.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 37 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Fig 7.2.7.2: Original Design Crude Mix yields
Fig 7.2.7.3: New Design Crude mix yields
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 38 of 79
7.2.7.1 Material Balance
The material balance for the 10 configuration cases with PPU and new design crude mix is
as follows:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 39 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.7.1.1: Feedstock Purchases (KTPA)
90%
CONVERSI
70%
90%CONV
ON+OHCU
70%
CONV+IND
ERSION+O
+INDMAX
CONV+FC MAX HIGH
HCU+LOB
LOW
HCU
CCR+PRU
S
CCR+PRU
+PPU
+PPU
90%
CONV+FC
HCU
90%
CONV+IND
MAX HIGH
CCR+PRU
+PPU
90%CONV
ERSION+V
GOHDT+IN
DMAX
LOW
CCR+PRU
+PPU
Case BA1
Case BA2
Case BA3
Case BA4
Case BA5
Case CA1
Case CA2
Case CA3
Case CA4
Case CA5
Crude blend
25000
25000
25000
25000
25000
25000
25000
25000
25000
25000
LNG
C7-C8 from
PNCP
C9+
STREAM
from PNCP
FUEL OIL
from PNCP
C4 from
PNCP
C5 from
PNCP
SURPLUS
H2
AVAILABLE
1476.7
1544
1668.2
1216.8
2028.4
1663.4
1898
1980
1944.7
1944.7
228
228
228
228
228
228
228
228
228
228
100
100
100
100
100
100
100
100
100
100
112
112
112
112
112
112
112
112
112
112
200
200
200
200
200
200
200
200
200
200
170
170
170
170
170
170
170
170
170
170
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
6.8
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
70%CONV
ERSION+V
GOHDT+IN
DMAX
LOW
CCR+PRU
+PPU
70%
CONVERSI
ON+OHCU
+INDMAX
LOW
CCR+PRU
+PPU
70%CONV
ERSION+O
HCU+LOB
S
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 40 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
MATHURA
REF.
NAPHTHA
AIR FOR
PTA
METHANOL
TO TAME
UNIT
ADDITIVE
FOR 90%
conv unit
150
150
150
150
150
150
150
150
150
150
239.5
239.5
239.5
239.5
239.5
239.5
239.5
239.5
239.5
239.5
9.6
9.6
9.6
8.2
9.6
9.6
9.6
9.6
9.3
9.3
2.365
3.659
3.671
3.022
0
0
0
0
0
0
Fuel gas from existing
refinery
Propylene from
existing refinery
Table 7.2.7.1.2: Product Sales (KTPA)
90%CONV
90%
ERSION+V CONVERS
90%CONV
GOHDT+I
ION+OHC
70%
ERSION+
NDMAX
U+INDMA
CONV+FC
OHCU+LO
LOW
X LOW
HCU
BS
CCR+PRU CCR+PRU
+PPU
+PPU
70%
CONV+IN
DMAX
HIGH
CCR+PRU
+PPU
70%CONV
ERSION+V
GOHDT+I
NDMAX
LOW
CCR+PRU
+PPU
70%
CONVERS
ION+OHC
U+INDMA
X LOW
CCR+PRU
+PPU
70%CONV
ERSION+
OHCU+LO
BS
90%
CONV+
FCHCU
90%
CONV+IN
DMAX
HIGH
CCR+PRU
+PPU
Case
BA1
Case BA2
Case BA3
Case BA4
Case BA5
Case CA1
Case CA2
Case CA3
Case CA4
Case CA5
82
84.8
84.8
84.8
84.2
86
84.8
84.8
84.8
84.4
110.7
79.4
79.4
79.4
99.7
110.72
79.4
79.4
79.4
108.5
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 41 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Poly Propylene
Mixed LPG'S
Total naphtha to PNCP
Naphtha stream to MS
pool
BS-VI Reg gasoline
Benzene
PTA
ATF
BS-VI HSD
High sul.f.oil
90% Conv. pitch
Bitumen
Coke
Product sulphur
Lube grade II 150n
Lube grade III 3cst
Lube grade III 6cst
Lube grade III 8cst
Lube grade II 500n
Lube grade II 70n
Ref. total losses
0
1035.1
2263.3
653.5788
1591.2
2262.496
547.4233
1566.3
1746
325.3039
1330.001
1746
0
925.8
1746
0
982.9
2289.3
652.6664
1543.1
2279.2
550.258
1499.4
1746
270.0874
1194.7
1746
0
900.1
1746
0
0
0
0
0
0
0
0
0
0
3427
24.6
700
1500
14360.1
0
149.7
499
866.9
311.8
0
0
0
0
0
0
2486.5
3997.5
24.6
700
1500
12303.7
0
106.3
360
866.9
304.8
0
0
0
0
0
0
2859.7
4209.7
24.6
700
1500
12748.4
0
164.4
360
866.9
401.5
0
0
0
0
0
0
2764.1
4139.8
24.6
700
1500
13542.7
0
164.9
360
866.9
361.8
0
0
0
0
0
0
2661.3
3559
24.6
700
1500
13448.9
0
135.8
499
912.6
322.3
404.2
80
125
50
246.9
74.8
2495.2
3627.4
24.6
700
1500
14876.3
0
0
360
866.9
317.8
0
0
0
0
0
0
2502.2
4133.6
24.6
700
1500
12491.8
0
0
360
866.9
302.1
0
0
0
0
0
0
2861.1
4428
24.6
700
1500
13072.6
0
0
360
866.9
413.9
0
0
0
0
0
0
2787.9
4319.7
24.6
700
1500
14043.08
0
0
360
866.9
361.9
0
0
0
0
0
0
2644.6
3877.8
24.6
700
1500
14127.3
0
0
360
866.9
341.4
414.5
80
125
50
252.7
77.8
2523.3
7.2.7.2 Capacity Utilization
The capacity of new units for the 10 configuration cases is tabulated below:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 42 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.7.2.1: Capacity of New Units (KTPA)
90%
CONV+FC
HCU
90%
CONV+IN
DMAX
HIGH
CCR+PR
U+PPU
90%CON
VERSION
+VGOHD
T+INDMA
X LOW
CCR+PR
U+PPU
90%
CONVER
SION+OH
CU+INDM
AX LOW
CCR+PR
U+PPU
70%
CONV+FC
HCU
70%
CONV+IN
DMAX
HIGH
CCR+PR
U+PPU
70%CON
VERSION
+VGOHD
T+INDMA
X LOW
CCR+PR
U+PPU
70%
CONVER
SION+OH
CU+INDM
AX LOW
CCR+PR
U+PPU
90%CON
VERSION
+OHCU+L
OBS
70%CON
VERSION
+OHCU+L
OBS
Case BA1
Case BA2
Case BA3
Case BA4
Case BA5
Case CA1
Case CA2
Case CA3
Case CA4
Case CA5
CDU/VDU
10000
10000
10000
10000
10000
10000
10000
10000
10000
10000
FHCU
3078.1
0
0
0
0
3319.1
0
0
0
0
VGO HDT
0
0
2436.5
0
0
0
0
3059.2
0
0
OHCU
0
0
0
2436.5
2462.2
0
0
0
3007.2
3048.3
DHDT
3393.8
4344
3736.5
3574.9
3468.3
4612
5190.5
4963
4777.8
4642.8
PSU
90 %
Conv.unit
0
1339.1
1142.1
666.8
0
0
1337.1
1148.3
543.8
0
1866.2
1325.2
2049.8
2056.8
1693.1
0
0
0
0
0
0
0
0
0
0
3358.2
2134.1
3271.7
3259.8
3214.5
70 %
conv. unit
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 43 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
INDMAX
0
3980.5
2525.5
1441.4
0
0
4103.8
2549.3
1170.9
0
0
0
0
0
1138.8
0
0
0
0
1160.9
0
0
0
0
1047
0
0
0
0
1067.2
619
622.9
656.4
848.3
845.9
753.6
706.7
793.5
1028.9
1030.6
617.7
621.7
655.1
846.6
844.2
752.1
705.2
791.9
1026.9
1028.5
944.7
648.4
712.6
767.1
823.9
946
684
774
840.1
882.1
929.1
637.7
700.8
754.5
810.3
930.4
672.7
761.2
826.3
867.5
0
751.5
0
0
0
0
751.3
0
0
0
0
448
2111.9
1071.8
0
0
237.8
2189.3
870.7
0
3107.7
6637.3
2932.8
3224.9
3528.7
2897.6
6744.2
2790
3004.9
3181
HGU
75.2
0
46.7
61.2
50.8
95.1
0
54.1
78.7
74.8
PPU
0
653.6
547.4
325.3
0
0
652.7
550.3
270.1
0
FPU FOR
LOBS
CIDW
FOR
LOBS
NHT FOR
CCR
CCR
NHT FOR
ISOM
ISOM
FGDS
VHP
STEAM
BOILER
HP
STEAM
BOILER
7.2.7.3 Power Import
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 44 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Power import for cases with PPU is as follows:
Table 7.2.7.3.1: Power Import
90%
90%CONV
90%
70%
CONV+IN +VGOHDT CONV+OH
CONV+IN
90%
90%CON
70%
DMAX +INDMAX CU+INDMA
DMAX
CONV+FC
V+OHCU+ CONV+FC
HIGH
LOW
X LOW
HIGH
HCU
LOBS
HCU
CCR+PRU CCR+PRU CCR+PRU+
CCR+PRU
+PPU
+PPU
PPU
+PPU
CASE NO.
Power Import
Case BA1 Case BA2 Case BA3 Case BA4 Case BA5 Case CA1 Case CA2
118.8
132.2
123.7
129.6
116
125.4
135.3
7.2.7.4 Gross Refinery Margin, Total Project Cost and simple payback period
GRM and total project cost for the configuration cases with new design crude mix is as follows:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
70%CONV+V
70%
GOHDT+IND
CONV+OHCU+IN 70%CONV+OH
MAX LOW
DMAX LOW CU+LOBS
CCR+PRU+P
CCR+PRU+PPU
PU
Case CA3
Case CA4
Case CA5
126.43
133.1
127.6
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 45 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.7.4.1: GRM, Total Project Cost and Simple Payback period
REVISED
90%
90%CONV
90%
70%
70%CONV+
BASE
CONV+IN +VGOHDT CONV+OH
CONV+IN
70%
90%
90%CON
70%
VGOHDT+IN
70%CONV+
CASE
DMAX +INDMAX CU+INDMA
DMAX
CONV+OHCU+IN
CONV+FC
V+OHCU+ CONV+FC
DMAX LOW
OHCU+LOB
FOR 25
HIGH
LOW
X LOW
HIGH
DMAX LOW
HCU
LOBS
HCU
CCR+PRU+
S
MMTPA
CCR+PRU CCR+PRU CCR+PRU+
CCR+PR
CCR+PRU+PPU
PPU
STUDY
+PPU
+PPU
PPU
U+PPU
CASE NO.
Case BA1 Case BA2 Case BA3 Case BA4 Case BA5 Case CA1
Case
CA2
Case CA3
Case CA4
Case CA5
14303.9
14423.0
13905.5
13747.5
GRM (RS CR/A)
5448.8
11434.7
13522.8
13265.5
12854.9
12150.8
12732.2
GRM (US$/BBL)
7.4
9.3
11.0
10.8
10.5
9.9
10.4
TOTAL PROJECT
COST (RS CR)
18195.8
21013.4
23230.3
22465.2
21283.3
20046.0
21773.6
24646.2
23487.6
23827.7
SIMPLE PAYBACK
(YEARS)
3.0
2.6
3.0
3.0
3.2
2.8
2.5
2.8
2.8
2.9
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
11.7
11.8
11.3
11.2
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 46 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.8 Shortlisting of Two Cases
Based on the above analysis following two cases were shortlisted:
 LP Case No. BA1 and LP Case No. CA1 were eliminated since there is no
petrochemical production potential for these configurations.
 LP Case No. BA2 and LP Case No.CA2 were eliminated since for these
configurations, Indmax unit is operating on straight run VGO and VR without any
treatment (upto feed CCR limit of 6 wt% and feed total nitrogen limit of 1800 wppm).
Hence these cases do not give flexibility in crude selection. A small variation in crude
quality may result in wide variation in yields and product properties of the Indmax unit,
which will directly affect the refinery margin.
 Moreover, SOx and NOx emissions from Indmax is high for these cases. Hence, flue
gas desulphurizer is additionally considered and hence control on SOx and NOx
emissions from Indmax unit is difficult.
 LP Case No. BA4 and LP Case No. CA4 were eliminated since for these
configurations, OHCU (with 70% conversion) is reducing feed to downstream Indmax
unit. Hence poly propylene production in these cases is lower, which results in lower
refinery margin.
 LP Case No. BA5 and LP Case No.CA5 were eliminated since there is no
petrochemical production potential for these configurations. Panipat refinery is already
petrochemical oriented (with adjoining PNCP) and adding another dimension to it with
LOBS production was not felt to be desirable.
Following two cases were shortlisted for IRR calculations:
1. Shortlisted Case 1 - LP Case BA3
2. Shortlisted Case 2 - LP Case CA3
Based on the following discussions:
 With VGO HDT upstream of Indmax unit, these configurations provide crude
selection flexibility.
 Due to maximum production of propylene, these configurations offer high refinery
margin.
 Since feed to Indmax unit is hydrotreated in upstream VGOHDT, SOx and NOx
emissions from Indmax unit are in reasonable limit.
 Estimated preliminary capex is high, but due to high margins, these cases offer
similar payback periods as for rest of the cases.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 47 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.9 Shortlisted Cases
The two shortlisted cases considered for the Panipat refinery expansion were:
Table 7.8.2 Shortlisted cases
Shortlisted Case-1
Shortlisted Case-2
90% CONV + VGOHDT +
INDMAX LOW CCR + PRU
+ PPU
70% CONV + VGOHDT +
INDMAX LOW CCR +
PRU + PPU
7.2.9.1 Material Balance
Refinery material balance for two shortlisted cases is as follows.
Table 7.2.9.1.1: Material balance for the two shortlisted cases
Shortlisted Case-1
Shortlisted Case-2
Bonny Lt.
1670
1670
Basrah Hy.
6670
6670
Kuwait
5420
5420
Maya
1250
1250
Saturno
0.00
0.00
Mangla
1200
1200
Dalia
470
470
Iran mix
1670
1670
Arab mix
2080
2080
Forcados
830
830
Escravos
830
830
Quaiboe
1250
1250
Zaffiro
830
830
Bombay Hi
830
830
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Crude blend
LNG
C7-C8 from PNCP
C9+ STREAM from PNCP
FUEL OIL from PNCP
C4 from PNCP
C5 from PNCP
Surplus H2 available
Mathura naphtha
Air for PTA
Methanol to tame unit
25000.0
1581.5
228.0
100.0
112.0
200.0
170.0
6.8
150.0
239.5
8.3
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 48 of 79
25000.0
1944.7
228.0
100.0
112.0
200.0
170.0
6.8
150.0
239.5
9.2
Additive for 90% Bottom
Processing unit
3.6
Total feed
27799.7
28160.2
Mixed LPG
1568.2
1517.1
Poly Propylene
533.5
528.2
Premium Gasoline
305.6
565.5
Propylene from existing
refinery
99.2
107.1
Fuel gas from existing
refinery
82.7
84.1
BS-VI Regular Gasoline
3895.5
Benzene
24.6
Template No. 5-0000-0001-T2 Rev. 1
0.0
3827.2
24.6
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
PTA
700.0
Total naphtha to PNCP
1746.0
Total light distillates
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 49 of 79
700.0
1746.0
8955.3
9099.8
35.8
36.4
1500.0
1500.0
BS-VI HSD
12844.6
13150.8
Total middle distillates
14344.6
14650.8
Total middle distillates
(wt% on crude)#
57.4
58.6
360.0
360.0
Coke
867.0
867.0
BHU Pitch
162.7
Total light distillates (wt%
on crude)#
ATF
Bitumen
Product Sulphur
374.9
0
393.7
Total heavy distillates
1764.6
1620.7
Total heavy distillates
(wt% on crude)
7.1
6.5
Ref. Total losses
2735.2
2788.9
2735.2
2788.9
10.9
11.2
Total loss
Total loss (wt% on crude)
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
27799.7
Total product
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 50 of 79
28160.2
Fig 7.2.9.1: Shortlisted case -1 yields
Fig 7.2.9.2: Shortlisted case -2 yields
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 51 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.9.2 Unit capacity of new units
Table 7.2.9.2.1: Capacity of new units (KTPA)
UNIT
CDU / VDU
UOM
MMTPA
CAPACITY FOR
SHORTLISTED CASE 1
CAPACITY FOR
SHORTLISTED CASE
2
10.0
10.0
PRU
KTPA
1136.4
1157.0
PPU
KTPA
537.7
547.3
NHT
MMTPA
1.4
1.6
CCR
MMTPA
0.7
0.8
ISOM
MMTPA
0.8
0.8
DHDT
MMTPA
1.2
1.3
KERO HDS
MMTPA
2.7
2.7
VGO-HDT
MMTPA
2.4
2.4
INDMAX
MMTPA
2.6
2.6
90% CONVERSION
MMTPA
2.0
0.0
70% CONVERSION
MMTPA
0.0
3.2
HYDROGEN
GENERATION UNIT
KTPA
45.0
67.0
TPD
555.0
630.0
SULPHUR
RECOVERY UNIT
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 52 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.9.3 Total Project Cost
Table 7.2.9.3.1: Total Project cost
SHORT LISTED
CASE-1
Units
Capital Cost (Rs Crore)
SHORT LISTED
CASE-2
22621.93
23994.20
7.2.9.4 Financial Results
Table 7.2.9.4.1: Financial Results
S No
Description
Short Listed Case-1
(Rs crores)
Short Listed Case-2
(Rs crores)
1
Capital Cost
22621.93
23994.20
2
Variable Operating Cost
31362.77
32055.49
3
Fixed Operating Cost
411.61
434.13
4
Total Operating Cost
31774.37
32489.62
5
Sales Revenue
38503.50
40290.22
6
IRR (Pre Tax) on Total Capital
22.13%
23.57%
7
IRR (Post Tax) on Total Capital
18.01%
19.08%
8
IRR (Pre Tax) on Total Equity
26.81%
28.79%
9
IRR (Post Tax) on Total Equity
21.40%
22.93%
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 53 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.9.5 Financial Parameters
Table 7.2.9.5.1: Financial Parameters
1
Construction Period
36 Months
2
Project Life
25 years
3
Debt / Equity Ratio
50:50
4
Expenditure Pattern
Equity before debt
5
Loan Repayment period
10 years
6
Moratorium Period
2 Year
7
Interest on Short Term Loan
9.35%
8
Capacity Build – up
1st year
60%
2nd year
80%
3rd year onwards
100%
9
Corporate Tax Rate
34.61
10
MAT
21.34
7.2.9.6 Observations and Inferences
Based on the results presented in the section above and basis adopted for study,
following points are concluded:
 Shortlisted case 2 has Superior Internal Rate of Return (IRR) as compared to
shortlisted case 1
 Project Capital Cost for shortlisted case 2 is comparable to the other short listed
case.
 No generation of Hydro processing Pitch to be disposed in shortlisted case 2 having
70% bottoms hydro processing unit as unconverted oil of 70% conversion unit is fed to
existing DCU.
 Yields of distillate products (MS+HSD) obtained is higher than (around 2%) in
shortlisted case 2 than the corresponding yield obtained in the other shortlisted case.
 Hence, based on the above observation shortlisted case 2 i.e was the recommended
case for this configuration study.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 54 of 79
7.2.10 Selected Case
Shortlisted case - 2 is recommended as the selected configuration case for IOCL Panipat
Expansion study. However, following modifications were proposed in the selected case
by client:
 Owing to low anticipated demand of polypropylene product the production of
Polypropylene was restricted to 450KTPA.
 Concern was also raised about the demand of MS in future. Decision was taken to
cap MS production at 3800 KTPA.

Demand of ATF was increased to 2000 KTPA.
 Minimum limit of Panipat Naphtha to PNCP was increased to 2200 KTPA from
previous limit of 60% of 2910 KTPA i.e 1746 KTPA.

Total MS production was made 3800 KTPA.
 Recommended case to be updated to produce minimum 25% and maximum possible
Premium gasoline by installation of an alkylation unit.
 In order to have adequate margins in the HGU and SRU capacities in the
recommended case higher sulfur content of typical crude 2.2 wt. % instead of 1.8 wt.% is
to be considered. .
 It was suggested that up to propylene storage shall be considered in refinery area of
P-25. New PPU shall be located in PNCP area as space of one train of PPU is already
available in PNCP area. Propylene shall be pumped from refinery to new PPU in PNCP
area. All associated utilities/offsite/warehouse requirement for New PPU shall be part of
PNCP area.
 Base case considered for this study was based on BS VI feasibility study report.
Even with the installation of a new TAME unit it was observed that there was no
production of premium grade gasoline in the base case. Hence base case was modified
to produce premium grade gasoline.
7.2.10.1 Modified Base Case
A feasibility study for BS VI fuel quality up gradation of IOCL Panipat Refinery at 15
MMTPA was conducted by M/S EIL in March, 2016. This BS VI model was utilized as
base case for this configuration study. However, due to less price differential
between regular and premium MS, it was observed that even after the installation of
TAME unit premium gasoline was not produced in the base case. Hence, base case
was modified to produce premium gasoline.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 55 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
a) Material Balance for modified base case
Table 7.2.10.1.1: Feedstock Purchases (KTPA) for modified base case
Feedstock purchases
KTPA
Crude blend
15000
LNG
1072.3
C7-C8 from PNCP
228
C9+ STREAM from PNCP
100
FUEL OIL from PNCP
112
C4 from PNCP
200
C5 from PNCP
170
SURPLUS H2 AVAILABLE
6.8
MATHURA REF. NAPHTHA
150
AIR FOR PTA
239.5
METHANOL TO TAME UNIT
9.6
TOTAL
17288
Table 7.2.10.1.2: Product Sales (KTPA) for modified base case
Product Sales
MIXED LPG'S
POLY PROPYLENE
PROPYLENE FROM EXISTING REF
FUEL GAS FROM EXISTING REF
KTPA
635.9
0.0
112.5
89.0
POLYMER GRADE PROPYLENE
PREMIUM GASOLINE
BS-VI REG GASOLINE
BENZENE
PTA
TOTAL NAPHTHA TO PNCP
JET
BS-VI HSD
HIGH SUL.F.OIL
BITUMEN
COKE
PRODUCT SULPHUR
REF. TOTAL LOSSES
TOTAL
0.0
270.0
1343.8
24.6
700.0
2045.6
1125.0
7738.6
225.0
360.0
908.9
142.4
1566.9
17288
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 56 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
b) Power import for revised base case
Table 7.2.10.1.3: Power import for revised base case
POWER IMPORT
MW
6.2
c) GRM for the revised base case
Table 7.2.10.1.4: GRM for the revised base case
GRM (RS CR/A)
5408.2
GRM (US$/BBL)
7.4
7.2.10.2 Selected case
The selected case of the Panipat Configuration study is as follows:
Table 7.2.10.2.1: Selected Case
Selected Case
70% CONV + VGOHDT + INDMAX LOW CCR + PPU ( 450
KTPA) + ALKYLATION UNIT
7.2.10.3 Material Balance for the selected case
The material balance for the selected case is tabulated below:
Table 7.2.10.3.1.1: Material balance for the selected case
Bonny Lt.
Basrah Hy.
Kuwait
Maya
Saturno
Mangla
Dalia
Template No. 5-0000-0001-T2 Rev. 1
1670
6670
5420
1250
0
1200
470
Copyright EIL – All rights reserved
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 57 of 79
Iran mix
Arab mix
Forcados
Escravos
Quaiboe
Zaffiro
Bombay Hi
Crude blend
LNG
C7-C8 from PNCP
C9+ STREAM from PNCP
FUEL OIL from PNCP
C4 from PNCP
C5 from PNCP
SURPLUS H2 AVAILABLE
MATHURA NAPHTHA FOR
AIR FOR PTA
METHANOL TO TAME UNIT
Total feed
Mixed LPG'S
Poly Propylene
Propylene from existing refinery
Fuel gas from existing refinery
Polymer grade propylene
Premium gasoline
BS-VI Regular gasoline
Benzene
PTA
Total naphtha to PNCP
1670
2080
830
830
1250
830
830
25000
1447.6
228
100
112
200
170
6.8
150
239.5
9.6
27663.5
725.3
450
110.7
84.8
0
3515.5
284.5
24.6
700
2735.8
Total Light distillates
8631.2
Total light distillates (wt% on crude)
ATF
BS-VI HSD
Total middle distillates
Total middle distillates (wt% on crude)
BITUMEN
COKE
PRODUCT SULPHUR
34.5
2000
12756.6
14756.6
59
360
867
367.5
Total heavy distillates
1594.5
Total heavy distillates (wt% on crude)
REF. TOTAL LOSSES
Total loss
Total loss (wt% on crude)
Total Product
6.4
2681.2
2681.2
10.72
27663.5
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 58 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Graphical representation of the distillate yields for the selected case is as follows:
Fig 7.2.10.3.1: Selected case distillate yields
7.2.10.4 Capacity Utilization of New Units
The capacity of new units for the selected case is tabulated below:
Table 7.2.10.4.1: Capacity of New units (KTPA)
UNIT
UNIT CAPACITY
CDU/VDU
10000.0
VGO HYDROTREATER
2199.3
DHDT-4
685.3
PROPYLENE SEPARATION UNIT
985.7
INDMAX
2207.8
NEW KERO HDS
2656.6
NHT FOR CCR AND ISOM
829.8
NEW CCR
624.1
NEW ISOM
201.1
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 59 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
NEW PPU
450.0
ALKYLATION UNIT
669.4
70% BOTTOM HYDROPROCESSING UNIT
2771.2
SULPHUR RECOVERY UNIT
2X324
HYDROGEN GENERATION UNIT
65.0
7.2.11 Product Blending Pools
7.2.11.1 Total Naphtha to PNCP
Following are the streams blending to make naphtha pool send to
PNCP
Table 7.2.11.1.1 : Components blended to make naphtha pool
Streams
Raffinate from Aromatic Complex
LSR Naphtha from CDU 1
LSR Naphtha From CDU 2
LSR Naphtha From CDU 3
Side cut from CDU 1
Side cut from CDU 2
Side cut from CDU 3
Naphtha cut from CDU 3
Heavy Naphtha from CDU1
Hy Nap from CDU2
Light naphtha From hydrocracking unit
DHT Heavy naphtha from DHDT
Naphtha from DHDT
Naphtha from DHDT
Naphtha from DHDT
TPD
185
150
1,026
920
551
838
1,036
5
530
333
214
26
273
527
25
Light naphtha from 70% bottom hydro processing unit
320
Light Naphtha from hydrocracking unit
948
C6+ of Coker light Naphtha from revamped prime G
260
VGO light naphtha from NEW VGO HDT
41
Total
Template No. 5-0000-0001-T2 Rev. 1
8,207
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 60 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.11.2 Product Qualities of Naphtha pool
Table 7.2.11.2.1: Product qualities of Naphtha Pool
Streams
Minimum
Product
Maximum
0.65
0.7076
0.74
450.9954
500
RVP INDEX
57.302
157.5407
MIN.RON
59.7535
MIN MON
59.0171
%V BENZENE, MAX
0.9877
AROMATICS, LV%
5.9662
% OFF AT 100C
60.3109
% OFF AT 180C
65.3999
SPECIFIC GRAVITY
SULFUR, PPM
% PARAFFINS
69
REID VAP PRESS, KPA
69.1618
28.7453
68.9473
7.2.11.3 BS VI Regular Gasoline
Following components are blended to make BS VI Regular Gasoline pool.
Table 7.2.11.3.1: Components blended to make BS VI Regular Gasoline
Component to Blend
TPD
Naphtha stream to MS pool
41
Reformate
284
Isomerate
227
ISAL product
266
Heavy aromatic from aromatic complex
35
Total
854
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 61 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.11.4 Product Qualities for BS VI Regular Gasoline
Table 7.2.11.4.1: Product Qualities for BS VI Regular Gasoline
Product Qualities
Specific gravity
Sulfur, PPM
RVP Index
RON
MON
%V BENZENE, MAX
AROMATICS, LV%
% OFF AT 70C
% OFF AT 100C
% OFF AT 100C
% OFF AT 180C
% OLEFINE
Reid vap press, KPA
Minimum
0.72
91.5
81.4
11
40
75
Product
0.7555
2.9561
112.0365
91.5
84.1329
1
35
15.4154
41.2619
79.4949
94.4401
6.0977
51.3406
Maximum
0.774
8
134.1558
1
35
45
70
21
60
7.2.11.5 BS VI Premium gasoline
Following components are blended to make BS VI Premium Gasoline pool.
Table 7.2.11.5.1: Components blended to make Premium gasoline pool
Components Blended
C7-C8
ALKYLATE
Naphtha streams to MS pool
REFORMATE
TPD
684
2,008
243
1,352
C5 RAFFINATE TO MS pool
183
ISOMERATE
892
INDMAX GASOLINE
1,491
ISAL PRODUCT
908
TAME
83
INDMAX HVY NAPHTHA
446
REFORMATE
NEW ISOMERATE
Total
Template No. 5-0000-0001-T2 Rev. 1
1,673
584
10,546
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 62 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.11.6 Product Qualities for BS VI Premium Gasoline
Table 7.2.11.6.1: Product Qualities for BS VI Premium Gasoline
Product Qualities
SPECIFIC GRAVITY
Minimum
Product
Maximum
0.72
0.7503
0.774
6.6632
8
101.5266
134.1558
SULFUR, PPM
RVP INDEX
MIN.RON
95.5
95.5
MIN MON
81.4
88.4075
%V BENZENE, MAX
AROMATICS, LV%
0.8551
1
35
35
% OFF AT 70C
11
19.2915
45
% OFF AT 100C
40
43.638
70
% OFF AT 100C
75
91.2858
% OFF AT 180C
95.2457
% OLEFINE
6.3563
18
REID VAP PRESS, KPA
47.147
60
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 63 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.11.7 ATF
Component to Blend
TPD
KMX KEROSENE
3,000
DESULPHURIZED KEROSENE from New KHU
3,000
Total
6000
7.2.11.8 Product qualities of ATF
Table 7.2.11.8.1: Product Qualities of ATF
Product Qualities
Minimum
Product
Maximum
0.775
0.8043
0.84
1067.1587
2500
AROMATICS, LV%
17.9169
22
FLASH INDEX
2.6833
FREZING PT.INDEX
1.528
SPECIFIC GRAVITY
SULFUR, PPM
CETANE INDEX
45.4434
CETANE NUMBER
19.1821
SMOKE PT.INDEX
41.6887
MERCAPTAN PPM
2.5
FLASH POINT, deg-F
SMOKE POINT, MM
FREEZE POINT, deg-C
Template No. 5-0000-0001-T2 Rev. 1
1.5471
50
156.0096
20
23.9873
-47.1899
-47
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 64 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.11.9 Product: XSD BS-VI HSD
Component to Blend
TPD
HSR naphtha from CDU 3
52
Kerosene from existing hydrocracking unit
1,407
Diesel from existing hydrocracking unit
2,724
DHT diesel
1,553
Heavy naphtha from hydrocracking unit
246
Kerosene from existing hydrocracking unit
Diesel from existing hydrocracking unit
1,536
2,622
Desulphurized diesel from DHDT
10,107
Heavy aromatics from aromatic complex
Desulphurized diesel from DHDT
53
5,998
VGO diesel
1,342
70% bottom hydro processing unit diesel
Desulphurized diesel from DHDT
70% bottom hydro processing unit Heavy Naphtha
3,166
2,007
480
Desulphurized kerosene from new KHU
Total
4,975
38,269
7.2.11.10 Product qualities of BS VI HSD
Table 7.2.11.10.1: Product qualities of BS VI HSD
Product Qualities
SPECIFIC GRAVITY
SULFUR, PPM
AROMATICS, LV%
REFUTAS VISC.INDEX @38C
REFUTAS VISC.INDEX @50C
FLASH INDEX
CETANE INDEX
CETANE NUMBER
POUR PT INDEX
% OFF AT 360C
FLASH POINT, deg-F
POUR POINT, deg-C
VISCOSITY, CST@38C
VISCOSITY, CST@50C
Template No. 5-0000-0001-T2 Rev. 1
Minimum
12.1179
46
95
107.5999
2.15
Product
0.8271
8
9.6317
12.9517
10.1758
7.7332
53.631
35.6444
1.8249
99.8386
118.3335
-6.6382
2.3445
1.7767
Maximum
0.845
8
18.4089
10.8635
4.5
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 65 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7.2.12 Capital cost for the selected case
Table 7.2.12.1 Capital cost for the selected case
Units
Selected case
Capital Cost (Rs Crore)
22900. 31
7.2.13 Financial analysis
Based on capital cost, operating cost and sales revenue, financial analysis has been carried
out to calculate Internal Rate of Return (IRR) and other financial parameters with a view to
establish the viability of the project.
For economic analysis, the current refinery product slate established by the LP model has
been considered. The sales realization as obtained for the refinery post 25.0 MMTPA has
been worked out. The parameters for performing financial analysis are tabulated below.
Table 7.2.13.1 : Financial Analysis for the selected case
S.No.
Case
Selected case (Rs crores)
1
Capital Cost
22900.31
2
Variable Operating Cost
30309. 83
3
Fixed Operating Cost
418 .68
4
Total Operating Cost
30728 .51
5
Sales Revenue
36612. 79
6
IRR (Pre Tax) on Total Capital
18.81%
7
IRR (Post Tax) on Total Capital
14.93%
8
IRR (Pre Tax) on Total Equity
22.17%
9
IRR (Post Tax) on Total Equity
17.00%
7.2.14 Sensitivities on the selected case
Various sensitivities were performed on the selected case. List of sensitivities is as below:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 66 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
1) Selected Case with LAB production
2) Selected case with no power import and new CPP
3) Selected case with no production of polypropylene
4) Selected case with 100% premium gasoline
5) Selected case with 90% capacity utilization
1) Selected case with LAB production
A sensitivity is performed on the selected case for the production of Linear Alkyl
Benzene (LAB) petrochemical. Sales price of LAB was revised by client as Rs
85828/MT. Results and analysis for this sensitivity is given below:
a) Material balance for case with LAB production
Feedstock purchases and Product sales of the sensitivity case with LAB as
compared to the selected case is given below:
Table 7.2.14.1: Feedstock Purchases (KTPA)
Feed Streams
Selected case
Sensitivity case with LAB
production
Crude blend
25000.0
25000.0
LNG
1447.6
1494.0
C7-C8 from PNCP
228.0
228.0
C9+ STREAM from PNCP
100.0
100.0
Fuel oil from PNCP
112.0
112.0
C4 from PNCP
200.0
200.0
C5 from PNCP
170.0
170.0
SURPLUS H2 available
6.8
6.8
Mathura Ref. Naphtha
150.0
150.0
Air for PTA
239.5
239.5
Methanol to TAME unit
9.6
9.6
TOTAL
27663.5
27710
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 67 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.14.2: Product Sales (KTPA)
Product Streams
Selected case
MIXED LPG'S
725.3
Sensitivity case with LAB
production
725.7
POLY PROPYLENE
450.0
450.0
PROPYLENE FROM
EXISTING REF.
110.7
110.7
FUEL GAS FROM EXISTING
REF.
84.8
84.8
PREMIUM GASOLINE
3515.5
3517.7
BS-VI REG GASOLINE
284.5
282.3
BENZENE
24.6
0.0
PTA
700.0
700.0
TOTAL NAPHTHA TO PNCP
2735.8
ATF
2000.0
2000.0
BS-VI HSD
12756.6
12706.0
LAB PRODUCT
0.0
65.7
BITUMEN
360.0
360.0
COKE
867.0
867.0
PRODUCT SULPHUR
367.5
367.7
REF. TOTAL LOSSES
2681.2
2728.3
TOTAL
27663.5
27710.0
b)
2744.0
Capacity of new units
The capacity of new units is as tabulated below:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 68 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.14.3: Capacity of new units (KTPA)
New units
Selected case
CRUDE UNIT #3
10000.0
Sensitivity case with
LAB production
10000.0
VGO HYDROTREATER
2199.3
2191.9
DHDT-4
PROPYLENE SEPARATION
UNIT
70% BOTTOM
HYDROPROCESSING UNIT
INDMAX
685.3
804.5
985.7
985.7
2771.2
2791.6
2207.8
2207.8
NEW KERO HDS
2656.6
2303.6
NEW NHT FOR CCR
625.3
621.3
NEW CCR
624.1
620.1
NEW NHT FOR ISOM
204.5
205.0
NEW ISOM
201.1
201.6
NEW PPU
450.0
450.0
ALKYLATION UNIT
669.4
669.4
LAB UNIT
0.0
65.7
c) Gross Refinery Margin
GRM for this sensitivity is as follows:
Table 7.2.14.4: GRM for case with LAB production
Economic Parameters
Selected case
Sensitivity case
with LAB
production
Gross Refinery Margin (Rs Crores / Annum)
13973.7
14104.0
Gross Refinery Margin (US $/ bbl of Crude)
11.4
11.5
Observations
Feed to the LAB unit is straight run kerosene streams from all the three Crude distillation
units, benzene as produced from the existing aromatic complex and hydrogen.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 69 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
It is observed that LAB unit operates at 66 KTPA with the available benzene. In order to
increase the production of LAB benzene import has to be considered. Around 39.1 KTPA of
benzene has to be imported to have LAB capacity of 170 KTPA.
Material balance for LAB case with benzene import is as given below:
Table 7.2.14.5: Feedstock Purchases (KTPA)
Selected
Feedstock Purchase
case
KTPA
Crude blend
25000.0
25000.0
LNG
1447.6
1539.2
C7-C8 from PNCP
228.0
228.0
C9+ STREAM from PNCP
100.0
100.0
FUEL OIL from PNCP
112.0
112.0
C4 from PNCP
200.0
200.0
C5 from PNCP
SURPLUS H2 AVAILABLE
MATHURA REF.NAPHTHA
170.0
6.8
150.0
170.0
6.8
150.0
AIR FOR PTA
239.5
239.5
METHANOL TO TAME UNIT
BENZENE
9.6
0
9.6
39.1
Table 7.2.14.6: Product Sales (KTPA)
Selected
Product Sales
case
725.3
MIXED LPG'S
KTPA
724.9
POLY PROPYLENE
450.0
450.0
PROPYLENE FROM EXISTING REF.
110.7
110.7
FUEL GAS FROM EXISTING REF.
84.8
84.8
PREMIUM GASOLINE
3515.5
3520.9
BS-VI REG GASOLINE
284.5
279.1
BENZENE
24.6
0
PTA
700.0
700.0
TOTAL NAPHTHA TO PNCP
2735.8
2755
ATF
2000
2000.0
BS-VI HSD
12756.6
12604.6
LAB PRODUCT
0.0
170.0
BITUMEN
360.0
360.0
COKE
867.0
867.0
PRODUCT SULPHUR
367.5
366.9
REF. TOTAL LOSSES
2681.2
2800.7
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 70 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.14.7: Capacity of new units (KTPA)
Capacity of new units
KTPA
CRUDE UNIT #3
10000.0
VGO HYDROTREATER
2199.3
DHDT-4
993.6
PROPYLENE SEPARATION UNIT
985.7
70% BOTTOM HYDROPROCESSING UNIT
2767.1
INDMAX
2207.8
NEW KERO HDS
1743.6
NEW NHT FOR CCR
615.3
NEW CCR
614.1
NEW NHT FOR ISOM
205.9
NEW ISOM
202.5
NEW PPU
450.0
ALKYLATION UNIT
669.4
LAB UNIT
170.0
Table 7.2.14.8: GRM for LAB case with benzene import
Economic Parameters
Selected case
Sensitivity case
with LAB
production (with
Benzene import)
Gross Refinery Margin (Rs Crores / Annum)
13973.7
14507.6
Gross Refinery Margin (US $/ bbl of Crude)
11.4
11.8
2) Selected case with no power import and new CPP
A sensitivity analysis considering no power import and a new captive power plant is
done. New GT will use RLNG as feed.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 71 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
a) Material Balance for case with no power import and new CPP
Table 7.2.14.9: Feedstock Purchase (KTPA)
Feedstock Purchase
Selected Case
Sensitivity case with
new CPP
Crude blend
25000.0
25000.0
LNG
1447.6
1596.4
C7-C8 from PNCP
228.0
228.0
C9+ STREAM from PNCP
100.0
100.0
Fuel oil from PNCP
112.0
112.0
C4 from PNCP
200.0
200.0
C5 from PNCP
170.0
170.0
Surplus H2 available
6.8
6.8
Mathura Ref naphtha
150.0
150.0
Air for PTA
239.5
239.5
Methanol to TAME unit
9.6
9.6
TOTAL
27663.5
27812.3
Table 7.2.14.10: Product Sales (KTPA)
Product Sales
Selected Case
Mixed LPG'S
Poly propylene
Propylene from existing refinery
Fuel gas from existing refinery
Premium gasoline
BS-VI Regular gasoline
Benzene
PTA
Total naphtha to PNCP
725.3
450.0
110.7
84.8
3515.5
284.5
24.6
700.0
2735.8
Sensitivity case with
new CPP
725.9
450.0
110.7
84.8
3516.5
283.5
24.6
700.0
2737.4
ATF
BS-VI HSD
Bitumen
Coke
Product sulphur
Ref. total losses
2000.0
12756.6
360.0
867.0
367.5
2681.2
2000.0
12764.7
360.0
867.0
368.2
2819.0
Total
27663.5
27812.3
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 72 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.14.11: Capacity of new units (KTPA)
Sensitivity case with
Capacity of new units
Selected Case
new CPP
CRUDE UNIT #3
10000.0
10000.0
VGO HYDROTREATER
2199.3
2190.8
DHDT-4
685.3
756.1
NEW PROPYLENE
SEPARATION UNIT
985.7
985.7
70% BOTTOM
HYDROPROCESSING UNIT
2771.2
2796.5
INDMAX
2207.8
2207.8
NEW KERO HDS
2656.6
2585.8
NEW NHT FOR CCR
625.3
623.4
NEW CCR
624.1
622.1
NEW NHT FOR ISOM
204.5
204.7
NEW ISOM
201.1
201.4
VHP STEAM BOILER (TPH)
NEW HP STEAM BOILER (TPH)
NEW PPU
NEW GT (MW)
NEW STG ( MW)
ALKYLATION UNIT
300
160
450.0
0.0
0.0
669.4
260
160
450.0
54.2
24.8
669.4
IRR for this case is given below:
All Cost in Rs Lakhs
Sensitivity case with new
CPP
1
Capital Cost
23539 02
2
Variable Operating Cost
30294 27
3
Fixed Operating Cost
429 43
4
Total Operating Cost
30723 70
5
Sales Revenue
36612 79
6
IRR on Total Capital
Pre-Tax
18.37%
Post-Tax
14.55%
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 73 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
7
IRR on Equity
Pre-Tax
21.56%
Post-Tax
16.47%
Observations
The capacity of New GT is 2x30 MW and new STG is 1x25 MW.
3) Sensitivity with no Polypropylene unit
Owing to low anticipated demand of polypropylene, a sensitivity is performed on the
selected case with no Polypropylene unit. Propylene produced from new units will be
sold at LPG price.
a) Material balance for case with no Polypropylene unit
Table 7.2.14.12: Feedstock Purchases (KTPA)
Feedstock Purchases
Selected case
Crude blend
25000
Sensitivity case
with no PPU
25000
LNG
1447.6
1385.405
C7-C8 from PNCP
228
228
C9+ STREAM from PNCP
100
100
FUEL OIL from PNCP
112
112
C4 from PNCP
200
200
C5 from PNCP
170
170
SURPLUS H2 AVAILABLE
6.8
6.832
MATHURA Ref NAPHTHA
150
150
AIR FOR PTA
239.5
239.4737
METHANOL TO TAME UNIT
9.6
9.575057
Total
27663.5
27601.29
Table 7.2.14.13: Product Sales (KTPA)
Product Sales
Selected case
MIXED LPG'S
PROPYLENE FROM EXISTING REFINERY
POLY PROPYLENE
725.3
110.7
450
Template No. 5-0000-0001-T2 Rev. 1
Sensitivity case
with no PPU
704.9
110.7
0.0
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 74 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
FUEL GAS FROM EXISTING REFINERY
POLYMER GRADE PROPYLENE
PREMIUM GASOLINE
BS-VI REG GASOLINE
BENZENE
PTA
TOTAL NAPHTHA TO PNCP
ATF
BS-VI HSD
BITUMEN
COKE
PRODUCT SULPHUR
REF. TOTAL LOSSES
Total
84.8
0
3515.5
284.5
24.6
700
2735.8
2000
12756.6
360
867
367.5
2681.2
84.8
430.4
3510.3
289.7
24.6
700.0
2718.8
2000.0
12763.9
360.0
867.0
367.3
2668.9
27601.3
27663.5
b) Capacity of new units
The capacity of new units is as follows:
Table 7.2.14.14: Capacity of new units (KTPA)
Capacity of new units
Selected case
Sensitivity case
with no PPU
CRUDE UNIT #3
10000
10000.0
VGO HYDROTREATER
2199.3
2109.2
DHDT-4
685.3
675.4
NEW PROPYLENE SEPARATION UNIT
985.7
934.3
70% BOTTOM HYDROPROCESSING UNIT
2771.2
2892.6
INDMAX
2207.8
2092.3
NEW KERO HDS
2656.6
2656.6
NEW NHT FOR CCR
625.3
624.3
NEW CCR
624.1
623.1
NEW NHT FOR ISOM
204.5
225.5
NEW ISOM
201.1
221.8
ALKYLATION UNIT
669.4
665.7
NEW PPU
450
0
c) Gross Refinery Margin
Table 7.2.14.15: GRM with no Polypropylene unit
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 75 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Economic Parameters
Selected case
Sensitivity case
with no PPU
Gross Refinery Margin (Rs Crores / Annum)
13973.7
11834.2
Gross Refinery Margin (US $/ bbl of Crude)
11.4
9.7
Observations
It is seen that with no Polypropylene production there is drop in GRM as compared to
the selected case.
4) Sensitivity with 100% Premium Gasoline
Table 7.2.14.16: Feedstock Purchases (KTPA)
Feedstock Purchases
Selected case
Crude blend
LNG
C7-C8 from PNCP
C9+ STREAM from PNCP
FUEL OIL from PNCP
C4 from PNCP
C5 from PNCP
SURPLUS H2 AVAILABLE
MATHURA NAPHTHA FOR
AIR FOR PTA
METHANOL TO TAME UNIT
Total
25000
1447.6
228
100
112
200
170
6.8
150
239.5
9.6
27663.5
Sensitivity case
with 100 %
Premium
Gasoline
25000
1753.602
228
100
112
200
170
6.832
150
239.4737
9.575057
27969.48
Table 7.2.14.17: Product Sales (KTPA)
Product Sales
Selected case
MIXED LPG'S
POLY PROPYLENE
PROPYLENE FROM EXISTING REFINERY
FUEL GAS FROM EXISTING REFINERY
POLYMER GRADE PROPYLENE
725.3
Template No. 5-0000-0001-T2 Rev. 1
450
110.7
84.8
0
Sensitivity case
with 100 %
Premium
Gasoline
778.3
450
110.7
84.8
40.42
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 76 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
BS -VI PREMIUM GASOLINE
BS-VI REG GASOLINE
BENZENE
PTA
TOTAL NAPHTHA TO PNCP
ATF
BS-VI HSD
BITUMEN
COKE
PRODUCT SULPHUR
REF. TOTAL LOSSES
TOTAL
3515.5
284.5
24.6
700
2735.8
3800
0
24.6
700
2964.4
2000
12756.6
360
867
367.5
2681.2
2000
12695.14
360
867
379.6
2715.1
27970.05
27663.5
b) Capacity of new units
The capacity of new units is as follows:
Table 7.2.14.18: Capacity of new units (KTPA)
Capacity of new units
Selected case
CRUDE UNIT #3
VGO HYDROTREATER
DHDT-4
NEW PROPYLENE SEPARATION UNIT
70% BOTTOM HYDROPROCESSING UNIT
INDMAX
NEW KERO HDS
NEW NHT FOR CCR
NEW CCR
NEW NHT FOR ISOM
NEW ISOM
NEW PPU
ALKYLATION UNIT
10000
2199.3
685.3
985.7
2771.2
2207.8
2656.6
625.3
624.1
204.5
201.1
450
669.4
Template No. 5-0000-0001-T2 Rev. 1
Sensitivity case
with 100 %
Premium
Gasoline
10000.0
2199.3
822.0
1073.4
3000.6
2405.0
2656.6
816.1
814.4
209.9
206.4
450.0
675.6
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 77 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
c) Gross Refinery Margin
Table 7.2.14.19: GRM with 100% Premium Gasoline
Economic Parameters
Selected case
Sensitivity case
with 100 %
Premium
Gasoline
Gross Refinery Margin (Rs Crores / Annum)
13973.7
13915.0
Gross Refinery Margin (US $/ bbl of Crude)
11.4
11.4
5) Sensitivity with 90% capacity utilization
A sensitivity was performed on the selected case with 90% capacity utilization.
a) Material Balance for case with 90% capacity utilization
Table 7.2.14.20: Feedstock Purchases (KTPA)
Feedstock Purchases
Selected case
Sensitivity case
with 90 % Capacity
Utilization
Crude blend
25000.0
22500.0
LNG
1447.6
1302.9
C7-C8 from PNCP
228.0
205.2
C9+ STREAM from PNCP
100.0
90.0
FUEL OIL from PNCP
112.0
100.8
C4 from PNCP
200.0
180.0
C5 from PNCP
170.0
153.0
Surplus H2 available
6.8
6.1
Mathura ref. naphtha
150.0
135.0
Air for PTA
239.5
215.5
Methanol to TAME unit
9.6
8.6
Total
27663.5
24897.2
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 78 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
Table 7.2.14.21: Product Sales (KTPA)
Product Sales
Selected case
MIXED LPG'S
POLY PROPYLENE
PROPYLENE FROM EXISTING
REFINERY
FUEL GAS FROM EXISTING REFINERY
725.3
450.0
Sensitivity case
with 90 %
Capacity
Utilization
652.7
405.0
110.7
99.6
84.8
76.3
BS VI PREMIUM GASOLINE
BS-VI REG GASOLINE
BENZENE
PTA
TOTAL NAPHTHA TO PNCP
3515.5
284.5
24.6
700.0
2735.8
3163.9
256.1
22.2
630.0
2462.3
ATF
BS-VI HSD
BITUMEN
COKE
PRODUCT SULPHUR
REF. TOTAL LOSSES
TOTAL
2000.0
12756.6
360.0
867.0
367.5
2681.2
27663.5
1800.0
11480.9
324.0
780.3
330.8
2413.1
24897.2
b)
Capacity of new units
The capacity of new units is as follows:
Table 7.2.14.22: Capacity of new units (KTPA)
Capacity of new units
Selected case
CRUDE UNIT #3
VGO HYDROTREATER
DHDT-4
NEW PROPYLENE
SEPARATION UNIT
70% BOTTOM
HYDROPROCESSING UNIT
INDMAX
NEW KERO HDS
10000.0
2199.3
685.3
Sensitivity case
with 90 %
Capacity
Utilization
10000.0
2199.3
685.3
985.7
985.7
2771.2
2207.8
2656.6
2771.2
2207.8
2656.6
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.2,Page 79 of 79
Refinery Configuration Study
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
NEW NHT FOR CCR
NEW CCR
NEW NHT FOR ISOM
NEW ISOM
NEW PPU (KTPA)
ALKYLATION UNIT
HGU-4 (KTPA)
SRU (TPD)
625.3
624.1
204.5
201.1
450.0
669.4
65
2X324
625.3
624.1
204.5
201.1
450.0
669.4
65
2X324
c) Gross Refinery Margin
Table 7.2.14.23: GRM with 90% capacity utilization
Economic Parameters
Selected case
Sensitivity case
with 100 %
Premium
Gasoline
Gross Refinery Margin (Rs Crores /
Annum)
13973.7
12576.4
Gross Refinery Margin (US $/ bbl of
Crude)
11.4
10.3
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 1 of 26
CHAPTER 7.3
PROCESS DESCRIPTION
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 2 of 26
7.3 Process description
Introduction
A brief process description along with a flow schematic for each of the process unit as
part of the selected refinery configuration is provided in this section. Schematic Flow
Diagram of each unit is attached in Annexure 3 of the feasibility report.
7.3.1

CDU/VDU

VGOHDT

INDMAX low CCR

Polypropylene Unit

Kero HDS

Diesel Hydrotreater

Naphtha Hydrotreater

Continuous Catalytic Reforming Unit

Isomerization unit

Alkylation Unit

90% bottom hydro processing unit

Hydrogen Generation Unit

Sour Water Stripper (Two stage)

Amine Regeneration Unit

Sulphur Recovery Unit
Crude/Vacuum distillation Unit
The typical scheme for Crude Distillation Unit is shown in Annexure III. (A328-79-41-00201) in Annexure 3.
Crude Distillation Unit
Crude Charge and Preheat Train-I
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 3 of 26
Crude from offsite storage is received at CDU/VDU plant battery limit. The crude is
subsequently heated in preheat exchangers by hot streams of CDU/VDU. Crude picks
up heat in the preheat exchangers before being routed to Crude desalter.
Desalter
A 2-stage electrostatic Crude Desalter to be provided for removal of salt and water from
the crude to desired level. The principle of desalting operation requires mixing of
preheated wash water in a mixing valve with the crude under controlled conditions and
to extract impurities.
Crude Preheat Train-II and Preflash
The crude from Desalter outlet is routed to the 2nd train of pre heat exchangers. Crude
picks up heat from hot streams of CDU/VDU and routed to Preflash drum. The liquid
separated in the Preflash drum is pumped to crude preheat train-III.
Crude Preheat Train-III
The pre flashed crude is heated in 3rd preheat train exchangers. Crude picks up heat
from hot streams of CDU/VDU and finally routed to crude heater.
Crude Heater
The preheated crude is fed to the crude heater and equally distributed to the heater
passes through pass balancer control valve. The total crude flow to the unit signal is
sent to the crude throughput controller, which sends signal to the furnace flow
controllers.
Crude Distillation Column
Heated and partially vaporised crude enters crude column through feed nozzle. The
column has five side draws, namely, Light Naphtha (SN), Heavy Naphtha (HN),
Kerosene (Kero), Light Gas Oil (LGO) and Heavy Gas Oil (HGO).
Crude Column Overhead Circuit
The overhead system consists of a two stage condensing system with wash water
circulation.
Sour water separated in reflux drum is partly returned as wash water for atmospheric
column overhead vapours. All the salt are dissolved in wash water and are purged out
of the system through sour water purge stream to sour water stripper unit. Additionally
Filming Amine is also injected in the crude column overhead line in order to protect the
overhead line.
Light/Heavy Naphtha Section
Naphtha is drawn as side product to side stripper. Stripper is provided with
thermosiphon reboiler to knock off light ends from naphtha. The CDU hot stream is
used as heating medium in reboiler. The bottom product of light/heavy naphtha stripper
is pumped to naphtha product cooler. The cooled product ex-product cooler is finally
routed to storage. The light hydrocarbon vapours leaving the naphtha stripper is
returned to the crude column.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 4 of 26
Kerosene Section
Kerosene product is drawn from crude column. The kero product flows to the kero
stripper under stripper level control. Kero stripper is a reboiled stripper using CDU hot
stream as reboiling medium. The light hydrocarbon vapours leaving the kero stripper are
returned to the crude column.
Light Gas Oil Section
LGO product and LGO CR stream is drawn as a single stream from crude column. One
stream as LGO product flows to the LGO Stripper under LGO stripper level control
where it is stripped using MP steam under flow control and the stripped vapours are
returned back to the Crude Column below.
Heavy Gas Oil Section
HGO product & HGO CR are drawn as a single stream from the Crude Column. One
stream as HGO Product flows to the HGO Stripper under stripper level control where it
is stripped using MP steam under flow control and stripped vapours are returned back to
the Crude Column.
Reduced Crude Oil Section
Stripped RCO from the column bottom is sent to the Vacuum Heater under level control
of atmospheric column bottom cascaded with the pass flow controller of Vacuum
Heater. MP steam under flow control is introduced as stripping steam of the Crude
column.
Crude Column Circulating Refluxes
Crude Column is provided with three Circulating Reflux streams for optimum
vapour-liquid internal traffic and heat recovery.
KERO CR:
Kero CR is drawn along with Kero product and is pumped by Kero CR pump. The heat
available in Kero CR is removed in crude preheat exchangers.
LGO CR:
LGO CR is drawn along with LGO product and is pumped by LGO CR Pump. The heat
available in LGO CR is removed in crude preheat exchangers and reboiler.
HGO CR:
HGO CR is drawn along with HGO product and is pumped by HGO CR Pump. The heat
available in HGO CR is removed in crude preheat exchangers and reboiler.
Product Rundown Section
Light/Heavy Naphtha Product Circuit
Light/heavy naphtha from naphtha stripper bottom is pumped by Light naphtha Product
pump for heat recovery and then to Naphtha Air cooler followed by naphtha Trim Cooler
before sending it for storage.
Kero Product Circuit
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 5 of 26
Kero product from Kero Stripper bottom is pumped by Kero Product pump. After heat
recovery, Kero product is further cooled in product coolers to required rundown
temperature and routed to storage.
LGO Product Circuit
LGO Product from LGO Stripper is pumped by LGO product Pump for heat recovery,
After Heat Recovery LGO product is further cooled in product coolers to required
rundown temperature and routed to storage.
HGO Product Circuit
HGO Product from HGO Stripper is pumped by HGO Product Pump. After heat
recovery, HGO product is further cooled in product coolers to required rundown
temperature and routed to storage.
RCO Product Circuit
Normally, Reduced Crude Oil (Crude Column residue, RCO) from Crude Column is
pumped to vacuum unit without any cooling. However, provision is kept to cool the hot
RCO stream in crude preheat circuit and coolers to facilitate to operate Crude unit alone
without Vacuum unit and route the RCO stream to storage.
Naphtha Stabilizer
Naphtha Stabiliser Column
The unstabilised naphtha consisting of all the fuel gas, LPG and Naphtha components is
pumped to Naphtha stabiliser column after preheating in the stabiliser feed/bottom
exchanger.
The overhead products are partially condensed in the Stabiliser Overhead Condenser.
Fuel gas and LPG are withdrawn from the overhead circuit. Fuel gas is routed to Fuel
Gas ATU and LPG is routed to LPG Treater.
Stabiliser column is a reboiled column using CDU hot stream as reboiling medium.
Stabilised Naphtha is further cooled in the exchanger to required rundown temperature
before routing the same to the storage.
Vacuum Distillation Unit
Vacuum Heater
Hot RCO from Crude column bottom is pumped by RCO pumps to Vacuum heater.
Each coil outlet of vacuum heater joins the transfer line and is routed to Vacuum
distillation column. The mixed vapour & liquid stream from the heater is introduced to
the Flash zone of Vacuum column.
Vacuum Distillation Column
Heated & partially vaporised RCO from Vacuum Heater enters the Vacuum Column. An
open ended tangential entry device and a large empty space above flash zone ensure
optimal vapour liquid separation.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 6 of 26
Stripping section:
The heavy hydrocarbons are stripped on valve trays. Subsequently the residue is
quenched by the vacuum residue product (Quench) to prevent after cracking in the
bottom compartment of the column. The various side streams taken out from Vacuum
Column are Vacuum Diesel, LVGO, HVGO and Slop Distillate.
Overhead Circuit:
Overhead vapour from vacuum column goes to the vacuum system. The vacuum
system is designed with a two stage ejector and a vacuum pump as the third stage.
Sour water from Hotwell is pumped by Hotwell Sour water pumps. Sour water
ex-Hotwell flows under interphase level-cascaded flow control for further treatment in
sour water stripper unit.
Vacuum Diesel Section:
Vacuum Diesel is drawn and pumped by Vacuum Diesel Product + CR + IR Pump and
is divided into 2 streams, namely, Vacuum Diesel IR, Vacuum Diesel CR + Product.
Vacuum Diesel IR is returned back under flow control to the Vacuum Column. The
product stream is cooled in the Vacuum Diesel Product + CR Trim Cooler
Gas Oil Section:
Gas oil is collected in collector tray and pumped by Gas oil IR pumps under level control
along with LVGO CR through spray nozzle distributor.
Light Vacuum Gas Oil Section (LVGO):
LVGO from collector tray is pumped by LVGO Product + CR + IR Pump and is divided
into 3 streams, namely, LVGO IR, LVGO CR and LVGO product. LVGO IR is returned
back under flow control to the Vacuum Column LVGO CR is cooled in crude/LVGO CR
Exchanger before returning back to the Vacuum Column along with Gas oil IR.
Heavy Vacuum Gas Oil section (HVGO):
HVGO from Collector tray is pumped by HVGO Product pumps and HVGO CR + IR
Pumps HVGO CR+ IR streams are split into two streams namely HVGO CR & HVGO
IR. HVGO product after exchanging heat with crude in crude preheats exchangers is
combined with LVGO and the combined VGO is cooled in tempered water cooler before
being routed to storage.
Wash section:
Slop from bed collector tray flows by gravity to the Slop Drum. Slop from this drum is
pumped by Slop Distillate Pump and is divided into 2 streams. Vapours rising from flash
zone are condensed by HVGO IR and collected as slop in collector tray. This liquid
provides the required washing in this section.
Vacuum Residue Section (VR):
(Vacuum Residue + Quench) from Vacuum Column bottom is pumped by VR + Quench
Pump to crude preheat train for heat recovery in Crude/VR+Quench exchangers. The
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 7 of 26
VR + Quench stream is then split into two streams and one stream as VR quench is
returned back to the Vacuum Column under flow control cascaded with vacuum column
bottom stream temperature controller.
Product Rundown section
Hot well vacuum slop oil:
Hot well vacuum slop oil from Hot well is pumped by hot well Slop Oil Pumps through a
coalescer and routed to downstream unit for further processing. Sour water from
coalescer is routed to sour water rundown line.
Vacuum diesel Product:
Vacuum Diesel from collector tray is drawn and pumped by Vacuum Diesel Product +
CR + IR Pump and is divided into 2 streams namely Vacuum Diesel IR, Vacuum Diesel
CR + Product. Hot Diesel stream after heat recovery is routed to DHT/DHDS and cold
stream after cooling to required rundown temperature is sent to the storage.
LVGO Product
LVGO from collector tray is pumped by LVGO Product + CR + IR Pump and is divided
into 3 streams namely LVGO IR, LVGO CR and LVGO product. LVGO is combined with
HVGO after heat recovery and the combined stream namely Vacuum Gas oil (VGO) is
routed to downstream unit. VGO is further cooled in cooler to required rundown
temperature before routed to storage.
HVGO Product
HVGO product from Collector tray is pumped by HVGO Pump. Subsequently HVGO is
combined with LVGO after heat recovery and the combined stream namely Vacuum
Gas oil (VGO) is routed to downstream unit.VGO is further cooled in cooler to required
rundown temperature before routed to storage.
Slop distillate product:
Slop from collector tray flows by gravity to the Slop Drum. Slop from this drum is
pumped by Slop Distillate Pump and is divided into 2 streams. One stream is returned
under flow control back to Vacuum Column as over flash while the second stream as
Slop Product is mixed with Vacuum residue.
Vacuum residue product:
(Vacuum Residue + Quench) from Vacuum Column bottom is pumped by VR + Quench
Pump to crude preheat train for heat recovery in Crude/VR + Quench exchangers. The
VR + Quench stream is then split into two streams. One stream as VR quench is
returned back to the Vacuum Column and other stream VR product is routed to residue
processing units such as SDA, BBU after heat recovery. VR product is further cooled to
required rundown temperature before routed to storage.
Tempered Water System
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 8 of 26
The cooling of the high pour point products like Vacuum residue & VGO is done by
tempered water to prevent exchanger congealing and to reduce exchanger
maintenance. Tempered water is pumped from Tempered Water Drum by Tempered
Water Pumps to VR/TW cooler and VGO/TW cooler.
Steam Generation Section
Make-up BFW is preheated by VR + Slop rundown stream in VR + Slop/BFW preheater.
This make-up BFW then splits into two parts. One of the make-up BFW stream is fed to
LP steam drum. The other Makeup BFW stream is fed to MP steam drum.
Blowdown
Blowdown from MP steam drum is flashed in a LP flash drum. The flashed condensates
from this LP flash drum and blowdown from LP steam drum is sent to Steam Blowdown
Drum where it is quenched with service water before draining it to storm sewer.
Chemical Dosing Facility
This system caters to CDU/VDU units.
Demulsifier
Demulsifier chemical is unloaded into demulsifier drums. The drum is provided with a
mixer which can be used for preparation of desired concentration levels of the chemical.
Demulsifier injection is done at the inlet of First stage desalter.
Filming Amine
Filming amine is unloaded into Filming amine drum. The drum is provided with a mixer,
which can be used for preparation of desired concentration levels of the chemical. It is
injected in the column overhead circuit to prevent corrosion.
Neutralising Amine
Neutralising Amine chemical is unloaded into Neutralising Amine drum. The drum is
provided with a mixer, which can be used for preparation of desired concentration levels
of the chemical. It is injected in the column overhead circuit for pH adjustment and to
prevent corrosion.
Caustic Solution
Caustic solution is required in the unit for caustic make-up to Vent Gas Caustic
Scrubber. 10 wt% caustic solution is obtained from OSBL, which shall be used for
make-up in Vent Gas Caustic scrubber. 5 wt.% Caustic solution might be required in the
unit to be injected into crude line downstream of desalter.
7.3.2 VGOHDT
The typical scheme for VGOHDT is shown in schematic flow diagram no A328-79-4100-202-A in Annexure 3.
VGO HDT unit shall treat the LVGO and HVGO from the CDU/VDU and gas oil from
bottom processing unit. Fresh feed is preheated, pumped and mixed with the preheated
recycle gas. The mixture is brought up to reaction temperature by the reaction furnace.
In the reactors the reactions are highly exothermic; therefore, the temperature at the
inlet of each bed is controlled by a quench gas injection. The reactor effluent is then fed
into the hot HP separator drum.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 9 of 26
The vapor phase from hot HP separator is cooled and water is injected at the inlet of the
air cooler. The air cooler effluent is collected in the cold HP separator drum where three
phases are separated. The sour water is removed and routed to the sour water stripper
system. The gas phase is sent to the recycle gas HP amine absorber where almost all
H2S is removed. The recycle gas is separated in two parts, one towards quench and the
other one with makeup gas to feed effluent exchanger. The hydrocarbon liquid phase
from the cold HP separator drum is routed to the LP separator. At LP separator, the
hydrocarbon liquid phase is combined with hot HP separator liquid phase and routed to
the inlet of the stripper where stripping is ensured by injection of medium pressure
steam at the bottom of the column. The overhead vapors from the stripper is partially
condensed by air and cooling water and collected in the reflux drum. The liquid
hydrocarbon phase is used part as reflux to the stripper and part is sent for gas
recovery.
The stripper bottom is heated and feeds the main fractionator where hydrotreated VGO
is stripped with superheated LP steam in the bottom section of the column. Fractionator
overhead stream is cooled and party refluxed back to the column and partly recovered
as unstabilized naphtha which is routed to Debutanizer. The diesel fraction is routed to
side stripper where part is recycled back to the column and part is obtained as diesel
product. Fractionator bottom product preheats the fresh feed, fractionator feed and
reboils the debutanizer and the deethanizer and also generates low-pressure steam and
is finally cooled in an air cooler before it is sent to storage.
LP separator vapor phase and stripper reflux drum vapor and liquid streams are routed
to Deethanizer via Deethanizer feed drum. Deethanizer bottom combines with
Fractionator reflux drum liquid phase to feed Debutanizer. Debutanizer overhead vapor
are totally condensed and part is routed back to column and net distillate is pumped as
LPG.
The purpose of Absorber is to maximize LPG recovery which is achieved by counter
flow of cooled naphtha coming from Debutanizer bottom. Absorber overhead vapor go
to LP amine absorber from where sweet gas is obtained.
7.3.3 INDMAX FCC with Propylene Recovery Unit
The typical scheme for INDMAX FCC unit and PRU is shown provided in Annexure 3
(A328-79-41-00-203 in Annexure 3.
INDMAX FCC is a fluidized catalytic process for selectively cracking a variety of feed
stocks to light olefins.
INMAX FCC is similar to conventional FCC in terms of basic process employed. But the
cracking are higher in INDMAX unit. The objective of this process is maximization of
LPG with higher selectivity towards propylene. LPG yield is typically 36-40 percent and
propylene is typically 20 wt%. Dry gas produced from this unit is rich in ethylene.
Hence, INDMAX unit provide opportunity for establishing downstream petrochemical
units. Propylene is recovered from LPG in downstream PRU and sent to downstream
Polypropylene unit. There is potential to use the dry gas rich in ethylene for the
production of styrene monomer after reacting with benzene to form ethyl benzene.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 10 of 26
To achieve the higher conversions, unit operates at higher severity with high reactor
temperature, higher quantity of dispersion steam in the reactor and higher catalyst to oil
ratio. The catalyst employed is zeolitic in nature. High ZSM-5 to the extent of ~ 15% is
added to achieve the desired conversions and propylene make. Some licensors offer
the catalyst impregnated with ZSM-5.
The INDMAX unit reactor regenerator system utilizes a reactor/riser, catalyst stripper,
1st stage regeneration vessel, 2nd stage regeneration vessel, catalyst withdrawal well
and catalyst transfer lines. Fresh feed, from upstream VGO HDT Unit, is finely atomized
with dispersion steam and injected into the riser through feed injection nozzles over a
dense catalyst phase. The small droplets of feed contact the freshly regenerated
catalyst and instantly vaporize. The oil molecules mix intimately with the catalyst
particles and crack into lighter and more valuable products.
As the reaction mixture travels up the riser, the catalyst, steam and hydrocarbon product
mixture passes through a riser termination device. This device quickly disengages the
catalyst from steam and product vapors. Reactant vapors are then ducted to the top of
the reactor near the reactor cyclone inlets, while catalyst is discharged into the stripper
through a pair of catalyst dip legs. The vapors with entrained catalyst pass through
single-stage high-efficiency cyclones. Reactor products, inerts, steam and a minute
amount of catalyst flow into the base of the main fractionator and are separated into
various product streams.
Below the dense catalyst bed in reactor vessel, a steam ring strips off volatile
hydrocarbon material from reacted catalyst particles. Stripped catalyst leaves the
reactor vessel through catalyst withdrawal pipes and enters the 1st stage regenerator
through a catalyst distributor that disperses the catalyst onto the bed surface. Catalyst
and combustion air flows counter currently in the 1st stage regenerator vessel. Partially
regenerated catalyst exits near the bottom of the vessel through a hollow stem plug
valve. A lift line conveys the catalyst into the 2nd stage regenerator vessel utilizing lift
air. CO-rich flue gas from the regenerator vessel exits through two-stage high efficiency
cyclones.
A mushroom grid evenly distributes the catalyst in 2nd stage regenerator vessel. Any
carbon remaining in the catalyst is completely burned off with an excess amount of air in
this regeneration stage. This results in high temperatures. Several design features like
external cyclones and a catalyst cooler are incorporated to minimize any mechanical
and/or physical temperature limitation. Hot regenerated catalyst flows into a withdrawal
well, through regenerated catalyst slide valves and into the "wye" section at the base of
riser. Here, it meets the hot feed. The INDMAX FCC gas recovery section employs a
low pressure drop main fractionator design with warm reflux overhead condensers to
condense the large amount of steam used in the convertor. A large wet gas compressor
is required relative to FCC operation because of high amount of dry gas and LPG. The
absorber and stripper columns, downstream of the wet gas compressor are specifically
designed for enhanced C3 recovery at relatively gasoline rates.
In addition to the above three products, the product fractionator separates the
catalytically cracked material into heavy naphtha, light and heavy cycle oils and catalyst
slurry. The heavy cycle oil is recycled back to the reactor. The catalyst slurry contains
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 11 of 26
some lighter hydrocarbon oil, clarified oil, which is subsequently separated and may be
recycled back to either the reactor or to the internal fuel oil pool.
The flue gas handling system downstream of the INDMAX regenerator requires
considerations no different than those of as FCC system. It consists of a flue gas slide
valve to control the differential pressure between the reactor and regenerator followed
by an orifice chamber. Heat is recovered by flue gas cooler in the form of high-pressure
superheated steam. Flue gas is de-sulphurized before sending out.
a) Propylene Recovery Unit
The typical scheme for PRU is shown in schematic flow diagram no A328-79-41-00-204A in Annexure 3.
The Feed to the PRU consists of INDMAX Propylene from upstream INDMAX unit. The
feed is first sent to a Depropanizer to recover a C3-rich cut from the propylene. The
Depropanizer bottom is routed to the refinery LPG pool.
The Depropanizer overhead is totally condensed against cooling water in the
Depropanizer Condenser and the bubble point liquid enters Depropanizer Reflux Drum.
The Depropanizer pressure is maintained by the overhead pressure controller which
permits hot vapor to bypass the Depropanizer Condenser. The drum is pressurized by
the hot vapor in order to maintain the reflux drum liquid at, or near, bubble point. If noncondensable build up in the reflux drum, they can be purged to the High Pressure
Separator on pressure control for LPG recovery. Water condensed in the tower
overhead system is routed to the Sour Water Flash Drum. The hydrocarbon liquid out of
the reflux drum is split into two streams; the Depropanizer Reflux & PP Mix .The reflux is
pumped back to the tower while the P-P Mix pumps send the mixed C3’s product stream
to the Propylene Recovery Unit (PRU).
PP Mix (Depropanizer overhead) sent for drying & for RSH/COS removal. The dry,
sulfur-free PP Mix is then sent on to the C3 Splitter system.
The PP Mix from the PP Mix RSH/COS Removal beds is fed to one of three feed trays
in the C3 Stripper. The C3 Stripper overhead is sent to the C3 Rectifier. The C3
Stripper uses high-capacity MD Trays. The C3 Stripper has an intermediate, or side
reboiler and bottom reboilers using hot water and LP steam as heating media. The
bottom of the C3 Stripper, C3 LPG, is cooled by cooling water in the C3 LPG Cooler and
sent on flow control to battery limits for storage.
The C3 Rectifier gets feed from the overhead of the C3 Stripper. The C3 Rectifier also
uses high-capacity MD trays. The bottoms of the C3 Rectifier are pumped by the C3
Splitter Transfer Pumps, on flow control reset by level, back to the C3 Stripper.
The overhead of the C3 Rectifier flows to the C3 Rectifier Condensers, condensed by
cooling water, and then to the C3 Rectifier Reflux Drum. There is a vapor-liquid
equilibrium in the reflux drum. The non-condensable vapor leaves the drum and is
recycled back to the High Pressure Separator Condenser in the gas plant. The pressure
in the reflux drum is controlled by a hot vapor bypass. It opens when the pressure is
low. It resets the vent recycle flow when the pressure is high. It is expected to always
have a small vent recycle flow. The vent recycle is on flow control and it is reset by
pressure. The polymer-grade propylene (PGP) is withdrawn below the tray #134. The
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 12 of 26
liquid is sent to the battery limit on flow control reset by reflux drum level, and on low
lever override when the level of the chimney tray is too low. The PGP is pumped and is
sent through the cooler and Arsine Removal Bed, for a final step in treatment. The
Arsine Removal Bed removes arsine and residual sulfur compounds. This bed is nonregenerable. The treated propylene is analyzed for propylene and propane and the
stream tested for contaminants.
7.3.4 Polypropylene Unit
The typical scheme for PPU is shown in schematic flow diagram no A328-79-41-00-205A in Annexure 3.
Fresh propylene is fed to the reactor along with the required catalyst, co-catalyst,
hydrogen and stereo-modifier. For production of two special grades with small ethylene
content, ethylene vapor is also fed to the reactor. Polymerization is carried out in a gas
phase stirred reaction. Liquid propylene entering the reactor vaporizes and thereby
removes the heat of exothermic reaction. Reaction gas is continuously removed from
the top of the reactor and filtered. Reactor overhead vapor (“Recycle Gas”) is
condensed and pumped back to the reactor as coolant. Non-condensable gases (mainly
H2 and N2) in the recycle gas are compressed and also returned to the reactor.
The polypropylene product powder is blown out of the reactor under reactor operation
pressure. The carrier gas and powder pass into the powder discharge vessel where
powder and gas are separated. The carrier gas is routed through a cyclone and filter to
remove residual powder, then scrubbed with white oil and sent to compression. Powder
from the discharge vessel is routed via rotary feeders to the purge vessels which are
operating in parallel. Nitrogen is used to purge the powder off residual monomers. The
overhead gas from the purge vessels is sent to a common membrane unit for
monomer/nitrogen recovery. As refrigerant for the membrane unit fresh Propylene is
used. The recovered nitrogen is sent back to the purge vessels for further use. The
condensed monomers from the purge gas are combined with the filtered carrier gas,
and then sent to scrubbing and subsequently to carrier gas compression. The PP
powder from the purge vessels is pneumatically conveyed by a closed loop nitrogen
system to the powder silos. The powder product from these silos is fed to the extruder
where polymer powder and additives are mixed, melted, homogenized and extruded
through a die plate, which is heated by hot oil. The extruding section is electrically/steam
heated.
Pelletizing of the final product is carried out in an underwater pelletizer where the
extruded polymers - after passing the die plate - are cut by a set of rotating knives. The
polymer/ water slurry is transported to a centrifugal dryer where polymer and water are
separated. Water is recycled to a pellet water tank, for which demineralized water is
used as make-up. The cooled pellets (~60°C) are pneumatically conveyed to the pellet
blending silos by an air conveying system. After homogenization in the blending silos
the pellets are conveyed to the bagging and palletizing system. The stream of carrier
gas (including recovered monomers from the membrane system) from compression is
split: half of the carrier gas is fed back to the reactors. The balance/remainder is sent to
an OSBL FCC unit for subsequent purification of the propylene. In addition this balance
carrier gas can be sent to the fuel gas system in case of FCC unit shut-down.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 13 of 26
7.3.5 Kerosene Hydrodesulphurization Unit
The typical PFD for KHDS unit is shown in diagram no A328-79-41-00-206 in Annexure
3.
Feed and make up gas compressor section
The kerosene feed to the unit is routed to the Feed Surge drum through a feed filter to
remove any carry over rust and polymeric components in feed followed by a feed
coalescer vessel, wherein drain water is taken out through the boot. The pressure in the
feed surge drum is maintained by fuel gas blanketing. The feed from the surge drum is
pumped to the Feed / Reactor Effluent Exchanger.
Make up Hydrogen from offsite supplies the chemical hydrogen, solution losses and the
mechanical loss of hydrogen to the unit. Make up H2 is routed to the Makeup H2
compressor KOD to separate any liquid. It is then compressed in the Makeup H2
compressor and routed to the feed.
Reactor Section
The preheated feed (including recycle and makeup gas) is brought to reactor
temperature in the Feed heater. The reactor inlet temperature is controlled by fuel firing.
The feed from heater is then routed to the reactor from the top (down flow). The effluent
from the reactor is routed to the Feed/Reactor Effluent Exchanger. The cooled effluent
from cooler is again heat exchanged with the Reactor Effluent Water Cooler and then
routed to the HP Separator. The separator is designed for 2 phase separation of gas
and kerosene liquid. The vapour phase gas is routed to a Recycle Gas Amine Absorber,
where the H2S is absorbed in lean MDEA. Lean amine from the Amine Regeneration
Unit is routed to the scrubber on flow control. The rich MDEA is routed back to the
Amine Regeneration Unit. The treated gas from the top of the absorber is routed to the
Amine KOD where entrained amine solution is removed from the gas. The gas from the
top of KOD is compressed in the Recycle Gas Compressor and fed to the feed along
with makeup gas.
The liquid kerosene is routed to the stripper column, before heat exchanging with
Stripper feed bottom exchanger.
Stripper Section
The liquid Kerosene from the separator drum is routed to the stripper column through a
Stripper feed/bottom exchanger. The stripper overhead vapours are condensed in the
Stripper overhead condenser. The overhead condenser minimizes the loss of C3, C4 and
C5 products to the fuel gas system. The Condenser outlet is routed to Stripper Reflux
Drum. The off gas is cooled by the off gas condenser and routed to OSBL. The
condensed overhead liquid is partly refluxed back to the stripper on flow control
cascaded with level in the Stripper reflux drum and balance routed as Naphtha product
to outside battery limit on flow control cascaded with stripper column overhead
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 14 of 26
temperature. A part of the bottom product is routed to Feed / Stripper Reboiler heater
via pump and is finally recycled back to the stripper.
The bottom product from the stripper is pumped by to the Stripper feed/bottom
exchanger XX-E-105 followed by Product rundown cooler and then finally to storage on
flow control cascaded with level column level control. The product is Hydro treated
Kerosene. The Hydro treated Kerosene is routed to storage through Salt filters XX-V108A/B and Clay filters XX-V-109A/B to remove any residual moisture and to ensure
water specifications in the final product.
7.3.6 Diesel Hydrotreater
The typical scheme for Diesel hydrotreater unit is shown in schematic flow diagram no
A328-79-41-00-207-A in Annexure 3.
The Diesel Hydrotreating Unit reduces the levels of sulfur and other contaminants in
diesel fuel products to meet regulatory specifications. The diesel feedstocks, including
straight-run diesel liquid streams from the Crude Distillation Unit and gas oil streams
from the bottom processing units, are mixed with recycle hydrogen and heated to the
reaction temperature in a fired heater. The feed mixture is passed over reactor beds
(cobalt-molybdenum/ nickel-molybdenum catalyst) with inter-bed quench.
Hydrogen sulfide and ammonia by-products are removed in the water wash section and
an amine contactor downstream of the reactor. The aqueous wash fraction containing
some hydrogen sulfide and ammonia is removed in a separator, and routed to the sour
water collection system. The H2S-rich amine from the contactor is regenerated before
being returned to the recycle gas scrubber as lean amine.
The sweetened gas from the amine absorber is recycled back to the recycle gas
compressor at the reaction section inlet. A stream of H2-rich gas through makeup gas
compressor meets the feed stream.
Liquid organic effluent from the reactor is routed to a stripper where distillates and
unstabilized naphtha is separated. Unstabilized Naphtha is routed to a stabilizer to
remove light end hydrocarbons, which are routed to the LPG treating plant for
processing and stabilized naphtha is further processed.
The stripper bottoms are separated into naphtha, kerosene, and diesel fractions in a
fractionator column. Naphtha-cut boiling point material is removed as the overhead
stream and is sent for treatment. The hydro treated kerosene and diesel streams are
sent to storage for blending.
7.3.7 Naphtha Hydrotreater Unit
The typical scheme for NHT unit is shown in schematic flow diagram no A328-79-41-00208 in Annexure 3.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 15 of 26
Naphtha Hydrotreater Section
Naphtha feed to NHT passes through a surge drum and a charge pump. It is then
combined with a H2-rich gas stream from the recycle gas compressor. The combined
feed enters the reactor feed/effluent exchanger, where the feed is heated. The heated
feed is brought up to the reaction temperature in a feed charge heater. The hot feed
down-flows through a fixed-bed reactor where the catalyst reacts with the feed to
remove sulphur as H2S, in presence of H2.The reactor effluent is cooled first in the
reactor feed/effluent exchanger and then in the product air cooler. Wash water is
injected into the reactor effluent upstream of the product air cooler so that any salt build
up in the condenser may be washed out. Reactor effluent flows out of the condenser at
a low temperature to ensure complete recovery of naphtha and enters the separator
The separator is provided with a mesh coalescer to ensure complete separation of
vapor, hydrocarbon liquid and sour water. Sour water is sent to SWSU, H2-rich vapor is
recycled back to the reactor through recycle gas compressor. A H2-rich makeup stream
is fed into the recycle stream through a makeup gas compressor. Liquid hydrocarbon
from separator is heated by heat exchange with stripper bottoms in stripper feed/bottom
exchanger and enters the stripper near its top. A steam reboiler provides stripper heat
duty. Overhead vapor from the stripper pass onto the stripper trim cooler partly
condenses and separates into three phases in the stripper receiver.
Net overhead gas from the stripper receiver is passed onto the refinery fuel gas system
after amine treatment to remove all H2S. Sour water from the receiver is sent to SWSU.
Hydrocarbon liquid from the receiver is sent back to the stripper as total reflux.
Hydrotreated sweet naphtha from stripper bottom is cooled in stripper feed/bottom
exchanger and then sent to naphtha/gasoline pool.
Naphtha Splitter Section
The Hydro treated Naphtha from Naphtha Hydro treating unit passes through a surge
drum and a charge pump. The feed enters the splitter column and is fractionated. The
heat to the fractionator is provided by a Reboiler. The Overhead vapors are condensed
in the overhead cooler into a Reflux drum. The overhead Light Naphtha is partially
pumped as reflux to the column and partially taken as Light Naphtha Product. The
Heavy Naphtha from the bottom of the splitter column is taken as Heavy naphtha
Product.
The Light Naphtha becomes feed for Isomerization Unit while as Heavy naphtha
becomes feed to CCR Unit.
7.3.8
Continuous Catalytic Reformer Unit
The typical scheme for CCRU unit is shown in schematic flow diagram no A328-79-4100-209 in Annexure 3.
The Catalytic Reforming Unit processes the heavy naphtha stream to make it more
suitable for the production of motor gasoline. The reforming process involves chemically
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 16 of 26
rearranging the hydrocarbon molecules to produce higher-octane materials.The octane
number is a key measure of motor gasoline performance. Hydrogen gas is produced as
a byproduct of reforming, and is used as feed to the Naphtha Hydrotreater Unit,
Distillate Hydrotreater Unit.
The heavy naphtha feed streams are mixed with recycle hydrogen, preheated by
exchange with reactor effluent, heated to reaction temperature in the charge heater and
sent to the first of a series of three to four reactors. Each reactor is preceded by a gasfired feed heater to maintain a constant inlet temperature profile for the individual
reactors (as reforming reactions that take place in the reactors are predominantly
endothermic). Effluent from the last reactor is heat exchanged with the combined feed,
condensed in the product trim cooler and sent to the separator. The reformed naphtha
product (reformate) is separated from the by-product hydrogen. A portion of the
hydrogen is compressed and recycled to be mixed with heavy naphtha feed material.
The remaining hydrogen is compressed for use in other refinery processing units.
The reformate product is fractionated in the debutanizer for separation of light ends. The
reformate liquid product is sent to storage, for use in motor gasoline blending. The
Catalytic Reforming Unit reactor catalyst is continuously regenerated in the Catalytic
Reforming Unit Catalyst Regenerator. The regeneration section of the reformer provides
a continual stream of clean coke-free active catalyst that is returned back to the
reactors. Continuous circulation of regenerated catalyst helps maintain optimum catalyst
performance at high severity conditions for long on-stream periods of reforming
operation. Catalyst regeneration takes place in dedicated equipment and uses nitrogen,
air, and perchloroethylene as regenerating agents. The Catalyst Regenerator performs
two principal functions - solid catalyst regeneration and circulation. Spent catalyst from
the final Catalytic
Reforming Unit reactor vessel is conveyed to the Catalyst Regenerator, where it is
regenerated in four steps:




Coke burning with oxygen,
Oxychlorination with oxygen and chloride,
Catalyst drying with air/nitrogen, and
Reduction of catalyst metals to "reduced" oxidation states.
Exiting the Catalyst Regenerator, the regenerated catalyst is conveyed back into the first
Catalytic Reforming Unit reactor. Small quantities of hydrochloric acid and chlorine are
generated in the Catalyst Regenerator. The vent gas from the Catalyst Regenerator is
scrubbed in two stages with caustic solution and water in the Vent Gas Wash Tower for
removal of acid gases, in particular hydrochloric acid. From the Wash Tower, the
cleaned.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 17 of 26
7.3.9 Isomerization Unit
The typical scheme for ISOM unit is shown in schematic flow diagram no A328-79-4100-210 in Annexure 3.
The fresh C5 /C6 feed is combined with make-up and re-cycle hydrogen which is directed
to a charge heater, where the reactants are heated to reaction temperature. The heated
combined feed is then sent to the reactor. Either one or two reactors can be used in
series, depending on the specific application.
The reactor effluent is cooled and sent to a product separator where the recycle
hydrogen is separated from the other products .Recovered recycle hydrogen is directed
to the recycle compressor and back to the reactor section. Liquid product is sent to a
stabilizer column where light ends and any dissolved hydrogen are removed. The
stabilized Isomerate product can be sent directly to gasoline blending.
7.3.10 Alkylation Unit
The typical scheme for ISOM unit is shown in schematic flow diagram no A328-79-4100-211 in Annexure 3.
It is used to convert isobutane and low-molecular-weight alkenes (primarily a mixture of
propene and butene) into alkylate, a high octane gasoline component. The process
occurs in the presence of a strong acting acid such as sulfuric acid as catalyst.
The product of the unit, the alkylate, is composed of a mixture of high-octane, branchedchain paraffinic hydrocarbons (mostly isoheptane and isooctane). Alkylate is a premium
gasoline blending stock because it has exceptional antiknock properties and is clean
burning. The octane number of the alkylate depends mainly upon the kind of alkenes
used and upon operating conditions.
The olefin feed to an alkylation unit generally originates from a FCCU and contains
butene, isobutene, and possibly propene and/or amylenes. The olefin feed is also likely to
contain diluents (such as propane, n-butane, and n-pentane), noncondensables (such as
ethane and hydrogen) and contaminants. Diluants in principle have no effect on the
reaction of alkylation but occupy a portion of the reactor and can influence the yield of
secondary reactions of polymerisation. Incondensable are from a chemical perspective
similar to diluents but they do not condense at the pressure and temperature of the
process, and therefore they concentrate to a point that must be vented. Contaminants
are compounds that react with and/or dilute the sulfuric acid catalyst. They increase acid
consumption and contribute to produce undesirable reaction products and increase
polymer formation. Common contaminants are water, methanol and ethanol.
The isobutane feed to an alkylation unit can be either low or high purity. Low purity
makeup isobutane feedstock (typically < 70% vol isobutane) usually originates from the
refinery (mainly from the reformer) and need to be processed in the deisobutanizer
(DIB). High purity feedstock (> 95% vol isobutane) normally originates from an external
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 18 of 26
De-isobutanizer (DIB) tower and is fed directly to the alkylation unit reaction zone. Such
isobutane feed does not normally contain any significant level of contaminants
Alkylation unit can be divided into five major sections: reaction, refrigeration, effluent
treating, fractionation and blowdown.
In the reaction section the reacting hydrocarbons (olefin feed with both fresh and
recycled isobutane) are brought into contact with sulfuric acid catalyst under controlled
conditions and at a temperature of 15.6 °C (60 °F). The feeds are treated to remove
impurities, especially water in order to reduce corrosion.
The heat of reaction is removed in the refrigeration section and the light hydrocarbons
are purged from the unit. In the effluent treating Section the free acid, alkyl sulfates and
di-alkyl sulfates are removed from the net effluent stream to avoid downstream
corrosion and fouling using a settler.
The sulfuric acid present in the reaction zone serves as a catalyst to the alkylation
reaction. Theoretically, a catalyst promotes a chemical reaction without being changed
as a result of that reaction. In reality, however, the acid is diluted as a result of the side
reactions and feed contaminants. To maintain the desired spent acid strength, a small
amount of fresh acid is continuously charged to the acid recycle line from the acid settler
to the reactor and an equivalent amount of spent acid is withdrawn from the acid settler.
In the fractionation section the unreacted isobutane is recovered for recycle to the
reaction section and remaining hydrocarbons are separated into the desired products.
The spent acid is degassed in an acid blowdown drum, waste water pH is adjusted and
acid vent streams are neutralized with caustic in a scrubber before being flared. Spent
acid goes to storage and periodically removed.
7.3.11 90% Bottom hydro processing unit
a)
Ebullated Bed Hydrocracker
The typical scheme for Ebullated bed HCU is shown in schematic flow diagram no A32879-41-00-212-A in Annexure 3.
Fresh hydrocarbon liquid feed is mixed with hydrogen and reacted within an expanded
catalyst bed that is maintained in turbulence by liquid upflow so as to achieve efficient
isothermal operation. Product quality is constantly maintained at a high level by
intermittent catalyst addition and withdrawal. Reactor products flow to the high pressure
separator, low pressure separator, and then to product fractionation. Recycled hydrogen
is separated and purified.
Process features include on-stream catalyst addition and withdrawal, thereby eliminating
the need to shut down for catalyst replacement. The expanded bed reactors operate at
near isothermal conditions without the need for quenches within the reactor.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 19 of 26
The reaction section uses a commercially proven low pressure hydrogen recovery
system. Separating the reactor effluent and purifying the recycled hydrogen at low
pressure results in lower capital cost and allows design at lower gas rates.
An available process option is the integration of Ebullated bed technology with distillate
hydrotreating or hydrocracking to produce high quality middle distillate products. This
can eliminate the need for additional downstream processing. Unconverted oil from an
Ebullated bed HCU can be sold as a stable, low sulfur fuel oil or sent to another heavy
oil conversion unit for further upgrading.
b) Slurry Hydrocracker
The typical scheme for Slurry Hydrocracker unit is shown in schematic flow diagram no
A328-79-41-00-213-A in Annexure 3.
Slurry Hydrocracker Unit converts vacuum residue and other heavy residue feedstocks
into higher valued distillate products. The heart of this technology is its reactor that can
operate at high temperatures required to maximize vacuum residue conversion. Reactor
conditions also allow the majority of the products to vaporize and quickly leave the
reactor, thereby maximizing the residence time of the feed’s heavier component and
minimizing any undesirable secondary cracking reactions which would produce lower
valued products and increase hydrogen consumption.
Catalyst Preparation Section
Catalyst is supplied to the refinery in the bulk form and stored in the raw catalyst storage
silo. The raw catalyst is then transferred from the storage silos to the hammer mills, then
to a second dust collector, weigh hopper, and finally into the slurry Mixing Tank and
then transferred to the Slurry Storage Tank. The slurry storage tank has a pump and
internal mixers to prevent any catalyst settling. The catalyst slurry is transferred to the
feed heater by the Slurry Injection Pumps.
Reaction Section
The reactor section configuration contains all of the equipment necessary to accomplish
the desired reactions, and then separate the resulting reactor effluent into its liquid and
gaseous components. It also includes the gas handling equipment necessary for
recirculation of the hydrogen rich recycle gas stream and addition of the required
makeup hydrogen. The feed flows to a vertical Feed Storage Drum and is pumped to
the reactor section by means of high head charge pumps. Fresh feed is pre heated and
split into parallel passes for each reactor in the system. Each feed pass is mixed with
small fraction of warm hydrogen rich recycle gas, heated in Feed Heater and enters the
bottom of the reactor and mixes with the hot recycle gas in the bottom zone of each
reactor. Significant back mixing occurs within the reactor. The back mixing maximizes
the residence time of the unconverted residue and minimizes the time the converted
products are in the reactor. To minimize gas holdup within the reactor, antifoam is
continuously injected near the top of the reactor. All products exit the top of the reactor
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 20 of 26
where they are immediately quenched to terminate any reactions. The overhead
streams from the reactor are sent to the Hot Separator.
Gas Liquid Separation Section
Effluent from the reactor is cooled by direct quenching with cool recycle gas upstream of
the Hot Separator. The Hot Separator prevents heavy, high boiling reactor effluent
components from causing water separation problems in the downstream Cold
Separator. The vapor from the Hot Separator is cooled by heat exchange with recycle
gas and reactor feed. Vapor is further cooled and wash water is added to prevent the
formation of salts. Final cooling of the vapor takes place in the air cooler. The effluent
then passes to the Cold Separator, where the sour water, hydrocarbon liquid and
hydrogen rich gas are separated into three phases. The liquid from the Hot Separator
flows o the Hot Flash Drum. The Hot Flash Drum vapor is cooled and sent to Cold Flash
Drum. The hot flash liquid is sent directly to the Stripper in the Fractionation Section.
The feed to the Cold Flash Drum are cold separator liquid, cooled hot flash drum vapor,
and cold separator sour water. The Cold flash drum vapor can be sent to Hydrogen
Recovery. The liquid is preheated and sent to Stripper in Fractionation Section.
The hydrogen rich gas from Cold Separator id recycled back to the Reaction Section by
the recycle gas compressor. Make up hydrogen is added to make up the consumption of
hydrogen in various reactions.
Fractionation Section
This section contains all of the equipment to recover the light gaseous products and
separate the liquid hydrocarbons recovered in the flash drums into the desired boiling
range fractions. This section typically includes a Stripper, a Debutanizer, an atmospheric
Fractionator and a vacuum Fractionator. The purpose of the steam-stripped Stripper is
to remove 99.99% of the hydrogen sulfide overhead with negligible loss of kerosene
boiling range material in the overhead liquid. The Stripper overhead vapor is sent to the
off gas treating section of the refinery. Liquid hydrocarbons recovered in the Stripper
overhead receiver are directed to downstream Debutanizer. The Stripper bottoms
product flows to the Atmospheric Fractionator via Fractionator Feed Heater. In
Atmospheric Fractionator naphtha and diesel is recovered. In order to recover vacuum
cuts, Atmospheric Fractionator bottom is routed to Vacuum Fractionator where vacuum
diesel, light vacuum gasoil and heavy vacuum gasoil are produced. Unconverted pitch is
obtained from Vacuum Fractionator bottom and sent to storage.
7.3.12 Hydrogen Generation Unit
The typical scheme for Hydrogen generation unit is shown in schematic flow diagram no
A328-79-41-00-214 A in Annexure 3.
In a refinery, the reaction chemistry of hydro-processing units used for upgrading the
straight run products or for increasing middle distillate yields rely on continuous supply
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 21 of 26
of high purity hydrogen. For this purpose Hydrogen Generation Unit is employed. The
working of unit is based on catalytic reforming and pressure swing adsorption (PSA)
system to produce 99.9 mole% pure hydrogen gas.
Hydrogen is produced by steam reforming of Regasified Natural Gas. LNG from surge
drum is pumped to LNG vaporizer. Vaporized LNG after mixing with recycled hydrogen
and superheated steam enters the pre-reformer. Superheated steam is added to adjust
the steam-carbon ratio, and the mixture is heated. The superheated feed-steam mixture
is distributed through multi-tubular reactor consisting of high alloy reformer tubes
containing nickel-based catalyst. Reforming reactions produces CO, CO2 and H2, and
heat for the endothermic reaction is supplied by a number of burners with PSA purge
gas and refinery fuel gas/ naphtha as fuel.
The reformed gas after being cooled undergoes shift conversion in shift converters.
These are cylindrical fixed bed reactors containing iron/chromium oxide or copper/zinc
oxide catalyst. Shift conversion reaction converts most of CO into CO2 and H2 in
presence of the catalyst. The heat removed from the converted process gas is used to
vaporize and further heat the feed, and preheat boiler feed water and demineralized
water (make-up). Downstream of Shift convertor is Process Condensate Separator
where condensate is separated and routed for BFW formation and steam generation.
Process gas is purified to remove inert gas impurities like CO2, CO, CH4, N2 and water
vapor by high-pressure adsorption of these impurities on molecular sieves, active
carbon and alumina gel in Pressure Swing Adsorption (PSA) system. All adsorbed
gases are removed during desorption and regeneration of the beds, and used as
reformer burners fuel.
7.3.13 Sour Water Stripper Unit (Two stage)
The typical scheme for SWS unit (two stage) is shown in schematic flow diagram no
A328-79-41-00-215-A in Annexure 3.
The rich amine stream from various units is received by a flash column in ARU battery
limit. This flash column allows for the removal of any associated hydrocarbon along with
some H2S which might also be liberated. This H2S is removed from the liberated
hydrocarbon vapors by means of a lean amine which is brought into contact with the
vapors in a counter current fashion over packed bed.
The rich amine from flash column free of any associated hydrocarbon is routed to amine
regenerator column through lean amine/rich amine exchanger. This preheated rich
amine stream contacts with reboiler vapors from bottom in a counter current fashion.
This ensures removal of H2S from rich amine stream. The vapors obtained from column
top are condensed using a reflux condenser, the water thus obtained is sent back to the
column as reflux thereby preventing the escape of ammonia to overhead system by
contacting the vapors moving up in the column in a counter current fashion. The acid
gases from column overhead circuit are routed to SRU in steam jacketed lines. In case
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 22 of 26
of SRU shutdown or high pressure in column, the acid gases can also be routed to acid
gas flare network.
7.3.14 Amine Regeneration Unit
The typical scheme for ARU is shown in schematic flow diagram no A328-79-41-00-216A in Annexure 3.
Rich amine from various absorber units is received in a flash column. Rich amine is
allowed to flash in the column to drive off hydrocarbons. Some H2S also gets liberated.
The liberated H2S is again absorbed by a slip stream of lean amine solution making
counter current contact with liberated gases over a packed bed.
From the flash column, the rich amine is pumped by rich amine pumps under flow
control to amine regenerator, after preheating in lean amine/rich amine exchanger. In
lean amine/rich amine exchanger, the heat is supplied to rich amine by hot lean amine
on shell side from the bottom of amine regenerator under level control. The lean amine
from lean amine/rich amine exchanger is further cooled in lean amine cooler and routed
to amine storage tank. Another part of lean amine from lean amine cooler is used as slip
stream to cartridge filter to remove solid particles picked up amine in the system. It is
also used to remove foam causing hydrocarbon substances and thereafter routed to
amine storage tank.
In amine regeneration column, reflux water enters the column top and descends down.
This prevents amine losses into the overhead and ensures complete removal of H2S.
The reboiler vapors from the bottom of the tower counter currently contacts the rich
amine and strips off H2S. The overhead vapors from regenerator are routed to
regenerator overhead condenser, where most of the water vapors condense and are
pumped by amine regenerator reflux pumps as reflux to the column. The acid gases are
routed to the SRU. In case the pressure goes high, acid gases are released to the acid
flare. Reboiler heat by LP steam is supplied to the column through amine regenerator
reboiler
7.3.15 Sulphur Recovery Unit
The typical scheme for sulphur recovery unit is shown in schematic flow diagram no
A510-79-41-00-217 in Annexure 3.
Acid gas from ARU passes through acid gas knock out drum, to remove any liquid
carryover, before feeding to main burner. Similarly, any liquid carryover in sour gas from
SWSU is removed in sour gas knock out drum.
The air to main burner is supplied by an air blower, which also supplies air to Super
Claus stage and sulfur degassing. The air to the main burner is exactly sufficient to
accomplish the complete oxidation of all hydrocarbons and ammonia present in the feed
gas and to burn as much H2S as required to obtain desired concentration. The heat
generated in the main burner is removed in the waste heat boiler by generating steam.
Then the process gas is introduced into the first condenser in which it is cooled, sulfur
vapor condensed and is separated from gas.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 23 of 26
Upstream of 1st Claus reactor, the process stream from waste heat boiler is heated in
1st steam reheater to obtain optimum temperature for the catalytic conversion. The
effluent gases from 1st reactor passes onto 2nd sulfur condenser where sulfur vapor is
condensed and uncondensed process gases pass to the 2nd steam reheater. Heated
vapors are again subjected to conversion in the 2nd Claus reactor followed by cooling in
the 3rd sulfur condenser. Then the process gas passes to the 3rd steam reheater and
the 3rd Claus reactor. Following reactions takes place inside the Claus reactor.
H2S + 3/2 O2
2H2S + SO2
2NH3 + 3/2 O2
SO2 + H2O + Heat
2H2O+ 3/n Sn + Heat
3H2O + N2
The sulfur formed remains in vapor phase and goes in polymeric reaction, which forms
polymeric sulfur in vapor phase. The predominate reactions are:
3S2
S6 + Heat
4S2
S8 + Heat
Some of these combustion reactions also take place in the burner section of the
reaction furnace. The lists of reactions taken place in the reaction furnace are given
below:
CH4 + 2O2
CO2 + 2 H2O
CO2 + H2S
COS + H2O
COS + H2S
CS2 + H2O
2H2S
2H2 + S2
COS + H2O
H2S + CO2
The unconverted H2S from the clause reactor is sent to the TGTU unit. Sulfur
condensed in condensers is routed via sulfur locks to sulfur cooler and drained into
sulfur degasification vessel. Stripping air is supplied to the spargers located at the
bottom side of the vessel. This strips off H2S from liquid sulfur and oxidizes the major
part of H2S to sulfur. Air leaving the stripping columns, together with H2S released from
sulfur degasification vessel, and is routed to TGT.Unit. Liquid Sulphur from pit is
pumped by sulphur pumps to Sulphur Yard.
Tail Gas Treating Unit
The Tail Gas Treating Section is required for the removal of sulphur compounds (H2S,
SO2, COS, CS2, elemental sulphur) from the tail gas from the Claus Section. This is
achieved by catalytic reduction of sulphur compounds to hydrogen sulfide and the
subsequent absorption of hydrogen sulfide in a regenerable absorption medium
(Amine).
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 24 of 26
Rich amine is subsequently treated in Amine Regeneration Section in order to release
the absorbed hydrogen sulfide which is recycled back to the Claus section for further
recovery of elemental sulphur. The H2S recycled allows an overall sulphur recovery
efficiency of 99.9% to be achieved.
Tail gas enters the hydrogenation reactor preheated at 130°C. H2 reducing gas is mixed
with Claus tail gas in the preheat effluent stream via a controller which is reset by the
SO2 concentration in the downstream of the hydrogen reactor. The effluent is preheated
under temperature controller by an electrical heater. A pre-sulfiding line is provided to
activate the TGU catalyst using acid gas from the acid gas KOD. Thus line is not used
for normal operation.
The hot preheated effluent passes through the catalyst bed of the hydrogenation reactor
where SO2 and other sulfur compounds are converted to H2S. Due to exothermic
reaction, the gas temperature increases. The reactor inlet temperature should be held
reasonably steady to provide stable conditions in the reactor. To avoid excessive outlet
temperature, the inlet gas may be controlled at somewhat lower temperature to
compensate for more SO2 and/or S in the tail gas feed. However, excessively low
reactor inlet temperature will result in poor conversion. The SO2 monitor at the reactor
effluent is observed to maintain an excess of ~3% H2. In addition, if the circulating water
in the quench loop shows the presence of finally divided sulfur this indicates incomplete
reaction and the SO2 has reached the column to form sulfur via the Claus reaction:
2H2S + SO2
3S + 2H2O
This behavior should be monitored as the presence of the sulfur not only means the
reaction is incomplete but the column can be plugged. Monitoring the pH of the quench
water provides a pre-warning to an impending problem. The pH should be maintained
near 7.0.
Hot reactor exit gas must be cooled before entering the absorber. A first stage gas
cooling is accomplished by generating steam at the TGU waste Heat Boiler, decreasing
the process gas temperature. BFW is fed to the shell side of the TGU-WHB on level
control and low pressure steam is generated. When the steam flow and/or BFW flow
rate changes, the water level in the steam generator varies. Rising level in the generator
indicates that the BFW flow rate is exceeding the rate of steam generation. In this case,
signal to the level control valve will decrease. If the steam generation exceeds the BFW
rate, level will decrease. In this case, signal to the level control will increase.
The process gas enters the quench column. The quench water recirculating loop
consists of the quench water pump, filter and water cooler. The cooler removes the heat
from the column, cooling the inlet gas. The water flow to the top of the column is
controlled after being filtered by quench water filter. Decreasing the water flow rate will
increase the bottom temperature. Increasing the water rate will increase the load in the
quench water circulation pumps and flow through the quench water cooler and column.
The quench column recirculation system has the provision to adjust the pH by addition
of caustic to the column recirculation line. The pH of the quench water to the water
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 25 of 26
pump is monitored and kept at a value between 7 and 9 in an effort to prevent corrosion
and inhibit colloidal sulfur formation. The water system should be visually inspected for
cloudiness. Low pH will indicate incomplete reduction of sulfur compounds.
Sour water condensed from the inlet feed is removed from the quench water loop via a
level controller from the quench column and is sent offsite to sour water storage. The
rate depends on the water in the Claus tail gas, water produced in the hydrogenation
reactor and the amount of water overhead in the quench column.
Downstream of these reactors, additional recovery of reduced sulfur is accomplished in
an amine absorber column that uses an aqueous methyl di-ethanolamine (MDEA)
solvent to scrub H2S from the TGTU tail gas. The overhead stream from this contactor,
containing very low sulfur levels, is sent to the tail gas thermal oxidizer for disposal. The
rich MDEA solvent is regenerated in the TGTU amine stripper and H2S is returned to
the inlet of the Claus SRU trains to be recovered. Regenerated MDEA solvent is
recirculated back to the TGTU amine absorber column.
Tail gas from TGU is routed to the incinerator where residual sulfur is converted to SO2
and discharged into the atmosphere.
The overhead line from the quench column flows to the absorber. The absorber is a
packed column and is designed to absorb practically all the H2S in the recirculating
Amine solvent. Amine absorber column that uses an aqueous methyl di-ethanolamine
(MDEA) solvent to scrub H2S from the TGTU tail gas. The overhead stream from this
contactor, containing very low sulfur levels, is sent to the tail gas thermal oxidizer for
disposal. The rich MDEA solvent is regenerated in the TGTU amine stripper and H2S is
returned to the inlet of the Claus SRU trains to be recovered. Regenerated MDEA
solvent is recirculated back to the TGTU amine absorber column.
The purpose of the incinerator system is to oxidize all the sulfur compounds in the tail
gas to SO2 and to vent the oxidized stream at high temperature and at a high elevation.
The incinerator system included the two primary sections:
In the incinerator burner, fuel gas is burnt with excess air to a temperature over 1650oC.
The temperature is sufficient to heat the tail gas from TGU to ~768oC. This temperature
is sufficient to oxidize the residual H2S and sulfur compound, while minimize NOx and
SO3 formation.
The effluent is discharged to the incinerator stack. The stack height of 60 meters is set
to ensure dispersion of SO2 and to meet ground level concentration limits.
Effluent tail gas from the TGU absorber is thermally oxidized with air to convert reaming
sulfur compounds to SO2. Fuel gas and excess air are combusted at high temperature
at the incinerator burner. Then it is mixed with the absorber overhead effluent tail gas in
the primary oxidation chamber. The fuel gas and air rates are adjusted to control the
temperature of the mixed and oxidized tail gas stream. The air is supplied by a
dedicated incinerator air blower. Excess air is used to ensure sufficient oxygen is
present to oxides the sulfur and other sulfur compound. Oxidation reactions are as
follows:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Process Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
H2S
+ 3/2 O2
2COS + 3 O2
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.3,Page 26 of 26
SO2 + H2O
2 CO2 + 2SO2
CO
+ ½ O2
CO2
CS2
+ 3 O2
2SO2 + CO2
Sn
+ nO2
n SO2
The incinerator effluent temperature is measured and used to adjust the flow rate of fuel
gas to maintain the desired operating temperature of 768oC. The incinerator is refractory
lined with an external thermal shroud to control the shell temperature. Skin
thermocouples are provided to monitor the shell temperature. The shell temperature
should be maintained between 149 – 350oC.
The air blower is designed to provide supply of air and stack while providing a minimum
of 2% excess O2 at an operating temperature of 768oC. Ambient air is drawn through
the inlet filter to remove solid debris and to protect against water during heavy rainfall.
The combustion gas from the burner and combustion chamber flow into the incinerator
where adequate residence time is provided for combustion. The incinerator stack vents
the effluent to the atmosphere. A SO2/O2 analyzer is provided to determine the SO2
and O2 in the effluent stream
.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Material Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.4,Page 1 of 10
CHAPTER 7.4
MATERIAL BALANCE
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Material Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.4
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.4,Page 2 of 10
Material balance
The material balance across the refinery and capacity utilization of various units have been
generated for Base Case for refinery capacity of 15 MMTPA, shortlisted cases and for the
selected case for 25 MMTPA refinery capacity.
7.4.1 Base Case
LP Model of the existing refinery at 15 MMTPA for 100% BS VI fuels is considered as the
base case of the refinery expansion study from 15 MMTPA to 25 MMTPA. All new facilities
in BS VI project i.e. additional TAME unit, revamped Prime-G, PX-PTA, change in PNCP
shared streams are considered as available for the expansion configuration study.
7.4.2 Major considerations in base cases
Following are the key considerations for the base case:

BS VI project is considered as executed for the expansion case study. Hence the
following facilities are considered as available:
Unit
Capacity (Design)
DHDT
2200 KTPA
HGU
44 KTPA
Sour water Stripper (2 stage)
56.7 m3/hr
ARU (MDEA based)
189 TPH
SRU + TGTU
225 TPD






100% BS VI fuels production.
SOx have been limited to 1000 Kg/hr (excluding PXPTA/PNCP).
Naphtha from refinery to PNCP shall be minimum 60% of 2910 KTPA (1746 KTPA)
of the total naphtha requirement in PNCP (2910 KTPA). These naphtha sales from
refinery shall be evaluated at 3 year average price.
Fuel gas from RFCC and DCU to be routed to PNCP for ethylene recovery at fuel
gas price.
There is no production of Premium gasoline for base case due to less price
differential between regular and premium MS.
For all the existing and new units, number of stream hours will be 8000hrs/yr.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Material Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.4,Page 3 of 10

Price of PFO from PNCP shall be considered as same as price of high sulphur fuel
oil.

Aromatics of C7-C8 stream from PNCP updated to 75 vol% in consultation with
client.
RON, RVP and aromatics for Prime G product updated to 87, 0.4 kg/cm2 A and 26
vol% respectively in consultation with client.
RON and RVP for isomerate updated to 87 and 1.0 kg/cm2 A in consultation with
client.
C-9 shall be routed only to prime G unit in order to saturate the revamped capacity
of Prime G. Bottom streams from new DCU light naphtha splitter located in
revamped Prime G is routed to HGUs.
C7-C8 stream from PNCP to refinery shall be considered as 228 KTPA for base as
well as expansion cases.
Paraffins in Full conversion hydrocracker light naphtha are same as that for
paraffins in OHCU light naphtha, i.e. 79 vol%.






Sulfur in feed to be limited to following:
S.NO
UNITS
SULPHUR LIMITS (WPPM) IN FEED
1
HGU-1
200
2
HGU-2
5900
3
4
5
6
7
HGU-3
DHDS
PREP DHDT
BS-VI DHDT
NHT FOR CCR
5900
17000
17300
18850
700
 Following limits in feed are to be maintained in DHDTs:
S.NO
UNITS
COKER DIESEL
(wt% of feed )
RFCC DIESEL
(wt% of feed)
COKER NAPHTHA
(wt% of feed)
1
PREP DHDT
33
5.1
1.4
2
BS-VI DHDT
41.6
8.4
8.9
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Material Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.4.3
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.4,Page 4 of 10
Refinery Expansion Cases
Various options were studied to establish refinery configuration at 25 MMTPA crude
processing, out of which two configurations were shortlisted for financial analysis. Material
balance of shortlisted cases is presented in the tables below.The two shortlisted cases
considered for the Panipat refinery expansion were:
Table 7.4.3.1 Shortlisted Cases
Shortlisted Case-1
Shortlisted Case-2
90% CONV + VGOHDT +
INDMAX LOW CCR + PRU +
PPU
70% CONV + VGOHDT +
INDMAX LOW CCR + PRU
+ PPU
Material balance for the two shortlisted cases is tabulated below:
Table 7.4.3.2 : Material balance for the two shortlisted cases
Shortlisted Case-1
Shortlisted Case-2
Bonny Lt.
1670
1670
Basrah Hy.
6670
6670
Kuwait
5420
5420
Maya
1250
1250
Saturno
0.00
0.00
Mangla
1200
1200
Dalia
470
470
Iran mix
1670
1670
Arab mix
2080
2080
Forcados
830
830
Escravos
830
830
Quaiboe
1250
1250
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Material Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.4,Page 5 of 10
Zaffiro
830
830
Bombay Hi
830
830
25000.0
1581.5
25000.0
Crude blend
LNG
C7-C8 from PNCP
C9+ STREAM from PNCP
FUEL OIL from PNCP
C4 from PNCP
C5 from PNCP
Surplus H2 available
Mathura naphtha
Air for PTA
Methanol to tame unit
228.0
100.0
112.0
200.0
170.0
6.8
150.0
239.5
8.3
1944.7
228.0
100.0
112.0
200.0
170.0
6.8
150.0
239.5
9.2
Additive for 90% Bottom
Processing unit
3.6
Total feed
27799.7
28160.2
Mixed LPG
1568.2
1517.1
Poly Propylene
533.5
528.2
Premium Gasoline
305.6
565.5
Propylene from existing
refinery
99.2
107.1
Fuel gas from existing
refinery
82.7
84.1
Template No. 5-0000-0001-T2 Rev. 1
0.0
Copyright EIL – All rights reserved
Material Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
BS-VI Regular Gasoline
3895.5
Benzene
24.6
PTA
700.0
Total naphtha to PNCP
1746.0
Total light distillates
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.4,Page 6 of 10
3827.2
24.6
700.0
1746.0
8955.3
9099.8
35.8
36.4
1500.0
1500.0
BS-VI HSD
12844.6
13150.8
Total middle distillates
14344.6
14650.8
Total middle distillates
(wt% on crude)#
57.4
58.6
360.0
360.0
Coke
867.0
867.0
BHU Pitch
162.7
Total light distillates (wt%
on crude)#
ATF
Bitumen
Product Sulphur
Total heavy distillates
Template No. 5-0000-0001-T2 Rev. 1
374.9
1764.6
0
393.7
1620.7
Copyright EIL – All rights reserved
Material Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.4,Page 7 of 10
Total heavy distillates
(wt% on crude)
7.1
6.5
Ref. Total losses
2735.2
2788.9
2735.2
2788.9
10.9
11.2
27799.7
28160.2
Total loss
Total loss (wt% on crude)
Total product
7.4.4
Selected case
The selected case of the Panipat Configuration study is as follows:
Table 7.8.4.1 : Selected Case
Selected Case
70% CONV + VGOHDT + INDMAX LOW CCR + PPU ( 450 KTPA)
+ ALKYLATION UNIT
7.4.4.1
Material Balance for the selected case
The material balance for the selected case is tabulated as follows:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Material Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.4,Page 8 of 10
Table 7.4.4.1.1 : Material balance for the selected case
FEEDSTOCK PURCHASES
KTPA
Bonny Lt.
1670
Basrah Hy.
6670
Kuwait
5420
Maya
1250
Saturno
0.00
Mangla
1200
Dalia
470
Iran mix
1670
Arab mix
2080
Forcados
830
Escravos
830
Quaiboe
1250
Zaffiro
830
Bombay Hi
830
Crude blend
25000.0
LNG
1447.6
C7-C8 from PNCP
228.0
C9+ STREAM from PNCP
100.0
FUEL OIL from PNCP
112.0
C4 from PNCP
200.0
C5 from PNCP
170.0
SURPLUS H2 AVAILABLE
6.8
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Material Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Mathura Ref naphtha
150.0
Air for PTA
239.5
Methanol to TAME unit
9.6
Total feed
27663.5
Mixed LPG'S
725.3
Poly Propylene
450.0
Propylene from existing refinery
110.7
Fuel gas from existing refinery
84.8
Polymer grade propylene
0.0
Premium gasoline
3515.5
BS-VI Regular gasoline
284.5
Benzene
24.6
PTA
700.0
Total naphtha to PNCP
2735.8
Total Light distillates
8631.2
Total light distillates (wt% on crude)
34.5
ATF
2000.0
BS-VI HSD
12756.6
Total middle distillates
14756.6
Total middle distillates (wt% on
crude)
59.0
BITUMEN
360.0
COKE
867.0
Template No. 5-0000-0001-T2 Rev. 1
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.4,Page 9 of 10
Copyright EIL – All rights reserved
Material Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
PRODUCT SULPHUR
Total heavy distillates
367.5
1594.5
Total heavy distillates (wt% on
crude)
6.4
REF. TOTAL LOSSES
2681.2
Total loss
2681.2
Total loss (wt% on crude)
10.72
Total Product
27663.5
Template No. 5-0000-0001-T2 Rev. 1
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.4,Page 10 of 10
Copyright EIL – All rights reserved
Utilities Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.5,Page 1 of 8
CHAPTER 7.5
UTILITIES DESCRIPTION
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Utilities Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.5
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.5,Page 2 of 8
UTILITY SYSTEMS
This chapter provides the utility requirements and description of utility systems for
various new process units envisaged for the shortlisted refinery configurations and
the selected configuration.
7.5.1 Shortlisted Cases
The two shortlisted cases considered for the Panipat refinery expansion were:
Table 7.5.1.1 Shortlisted Cases
Shortlisted Case-1
Shortlisted Case-2
90% CONV + VGOHDT +
INDMAX LOW CCR + PRU
+ PPU
70% CONV + VGOHDT +
INDMAX LOW CCR +
PRU + PPU
7.5.2 Utility consumption of the shortlisted cases
Utility consumption (continuous and intermittent) for the above mentioned cases is
estimated based on EIL in-house data and is tabulated in the Table 7.5.2.1 below:
Table 7.5.2.1 : Utility consumption of the shortlisted cases
Utility System
Unit of
Measure
Short listed case-1
Short listed case-2
Raw Water System
m3/hr
3000
3000
Cooling Water System
m3/hr
60000
60000
Condensate Polishing
Unit
m3/hr
190
205
300
300
105
160
26200
26200
7600 Nm3/hr
7600 Nm3/hr
Utility Boiler – VHP Steam TPH Steam
Utility Boiler – HP Steam
TPH Steam
Compressed Air (IA/PA)
System
Nm3/hr
Nitrogen Plant
Capacity
Flare
Effluent Treatment Plant
(Zero Liquid Discharge
Template No. 5-0000-0001-T2 Rev. 1
Stack Sizes 56” (Hydrocarbon), 16”
& Height (Sour) & 150m height
-
For treating Oily Water,
Sanitary Effluent and
56” (Hydrocarbon), 16”
(Sour) & 150m height
For treating Oily Water,
Sanitary Effluent and
Copyright EIL – All rights reserved
Utilities Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
achieved through
consideration of
Evaporator and
Crystallizer)
CRWS along with Spent
Caustic, Boiler Blow
down and CW Blow
down
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.5,Page 3 of 8
CRWS along with Spent
Caustic, Boiler Blow
down and CW Blow
down
Table 7.5.2.2 Power import
Unit of Measure
Short listed
case-1
Short listed case-2
MW
113
101
Power import
Since the proposed secondary units for 25 MMTPA shall come up at a new location,
new utility systems are envisaged.
7.5.3 Selected case
The selected case of the Panipat Configuration study is as follows:
Table 7.5.3.1 : Selected Case
Selected Case
70% CONV + VGOHDT + INDMAX LOW CCR + PPU ( 450
KTPA) + ALKYLATION UNIT
7.5.4 Utility consumption of the selected case
Utility consumption (continuous and intermittent) for the above mentioned cases is
estimated based on EIL in-house data and is tabulated in the Table 7.5.4.1 below.
Since the proposed secondary units for 25 MMTPA shall come up at a new location,
new utility systems are envisaged.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Utilities Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.5,Page 4 of 8
Table 7.5.4.1 : Utility consumption of the selected case
Utility System
Unit of Measure
Selected Case
Raw Water System
m3/hr
3000
Cooling Water System
m3/hr
60000
Condensate Polishing Unit
m3/hr
205
Utility Boiler – VHP Steam
TPH Steam
300
Utility Boiler – HP Steam
TPH Steam
160
Compressed Air (IA/PA)
System
Nm3/hr
Nitrogen Plant
Capacity
Flare
Stack Sizes & Height
Effluent Treatment Plant (Zero
Liquid Discharge achieved
through consideration of
Evaporator and Crystallizer)
-
26200
7600 Nm3/hr
56” (Hydrocarbon), 16”
(Sour) & 150m height
For treating Oily Water,
Sanitary Effluent and
CRWS along with Spent
Caustic, Boiler Blow
down and CW Blow
down
7.5.4.1 Power import
During the course of study, it was decided that the New PPU shall be located in
PNCP area as space of one train of PPU is already available in PNCP area.
Propylene shall be pumped from refinery to new PPU in PNCP area. All
associated utilities requirement for New PPU shall be part of PNCP area.
Power import required for new units of the selected case is as tabulated below.
Additional Power requirement of the new PPU is 20.5 MW.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Utilities Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.5,Page 5 of 8
Table 7.5.4.1.1 Power import
Unit of Measure
Selected Case
Power import
7.5.5
MW
71
Raw Water System
Untreated Raw water storage is considered as existing. A Raw water treatment plant
corresponding to 3000 m3/hr is considered for selected case. Treated Raw water is
put to the following uses:



7.5.6
Cooling water make-up
Service water
Feed to RODM plant
Cooling Water System
The Cooling water requirement for two shortlisted cases is provided in table above.
The cooling water system envisaged for the selected case is tabulated above.
Cooling Tower
Cooling Tower with 17 cells (16W+1SB), each of capacity 4000 m3/hr has been
provided to meet the cooling water requirement.
7.5.6.1
Recirculating Cooling water Pumps
To cater the cooling water requirement, 11 pumps (8 W+3 SB), each of capacity
4000 m3/hr has been considered.
Type
:
Horizontal centrifugal
Type of Drive
:
Electric Motor
No. of pumps
:
8 operating + 3 stand by
Capacity
:
9000 m3/hr. each
7.5.6.2
Cycles of Concentration
Under the maximum levels of the specified conditions, the cooling water system is
considered to operate at 4 cycles of concentration.
7.5.6.3
Side Stream Filter
Side stream filters with total capacity based on 1.0 – 2.0 % of the cooling tower
capacity are considered so as to maintain the suspended solids contents within the
stipulated limits in the recirculating cooling water. Accordingly two side stream filters
each of capacity 430 m3/hr both operating simultaneously are considered.
7.5.6.4
Cooling Water Makeup
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.5,Page 6 of 8
Utilities Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Based on 2.5 – 3.0 % makeup, cooling water makeup requirement is about1350
m3/hr. Accordingly 7 pumps (5W+2SB), each of capacity 365 m3/hr has been
considered.
7.5.7
Steam, Power, BFW and DM water
Steam Requirement:A VHP and HP steam boiler to meet the steam requirement of new units has been
considered as tabulated in table 7.5.4.1 above.
Power Requirement:Power import from grid is envisaged to meet the power requirements mentioned in
Table. However, the cost to bring power at refinery battery limit is excluded from the
scope of current study.
BFW Requirement:Deaerator facility for BFW generation of 208.2 TPH has been considered for the
selected case.
DM Water:In order to have zero effluent discharge from the refinery, DM water requirement will
be met by the Effluent treatment plant. DM water quantity produced from the zero
discharge ETP will reduce the DM water quantity to be produced from raw water with
consequent reduction in raw water consumption during normal operation
Condensate Polishing Unit
A CPU has been considered to polish the condensate generated from the new units.
Hence, a CPU of feed 205 TPH is considered for selected case.
7.5.8
Fired Duty
The Fuel requirement for the new units envisaged in this study would be met by
imported RLNG, fuel oil & fuel gas generated internally from the various new units.
7.5.9
Compressed Air System
The compressed air is required for following usage:



As Instrument Air
As Plant Air
As service air for hose stations and for other requirements.
Feed to Nitrogen Plant
The requirement of IA/ PA and N2 for present study is tabulated in Table 7.5.4.1
above.
a) Air Compressor:-
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Utilities Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Type
Type of Drive
Capacity
No.
Discharge Pressure
:
:
:
:
:
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.5,Page 7 of 8
Integrally geared centrifugal
Electric Motor
13100 Nm3/hr.
3 (2W+1S)
6.8 Kg/cm2 (g) at compressor B/L
b) LP Air Receiver:Part of the Compressed air from the compressors will be sent to a common LP
Air Receiver to remove any water being condensed. Air from the LP Air Receiver
will then be routed accordingly, to meet the requirement of instrument air.
Broad specifications for the LP Air Receiver are given below:Type
Height
Diameter
:
:
:
Vertical
7m
2.8 m
c) Instrument Air Dyer:To meet the requirement of Instrument air, 4 driers each of capacity 5000 NM3/hr
have been envisaged.
7.5.10 Nitrogen System
The inert gas (Nitrogen) is required in the refinery for initial purging, dry out and for
catalyst regeneration. The inert gas is also required for blanketing and for flare
header purging.
The Nitrogen requirement of the shortlisted options is tabulated in the table 7.5.1
above. A cryogenic N2 plant is considered for continuous and intermittent nitrogen
requirement. Liquid Nitrogen storage along with vaporizer is considered for meeting
the startup nitrogen requirement of the various units.
Nitrogen system envisaged for selected case is as follows:
a) A cryogenic N2 plant of capacity 7600 NM3/hr.
b) 3 liquid nitrogen vessels, each of capacity 150 m3) along with nitrogen
Vaporizer of 2100 Nm3/hr.
Nitrogen system envisaged for Slurry hydrocracker case is as follows:
a) A cryogenic N2 plant of capacity 2800 NM3/hr.
b) Five liquid nitrogen vessels, each of capacity 200 m3 (considering simultaneous
startup of Slurry hydrocracker unit and Hydrogen unit) along with nitrogen Vaporizer
of 15180 Nm3/hr.
7.5.11 Flare System
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Utilities Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.5,Page 8 of 8
The flare system will be provided for safe disposal of combustible, toxic gases which,
are relieved from process plants and off sites during start - up, shutdown, normal
operation or in case of an emergency such as:








Cooling water failure
General Power failure
Any other operational failure
Blocked outlet
Reflux failure
Local power failure
Tube rupture
External fire
The existing flare system is expected to be inadequate to handle the flare load post
expansion. Hence, it is recommended to put up a new flare system under the
expansion project. Under this study, preliminary Flare load are estimated based on
EIL in-house data and new flare system has been considered to relieve the loads
appropriately.
New flare system (with 56” diameter flare stack for Hydrocarbon) along with water
seal drum, molecular sieve, flare header and main flare KOD has been considered.
The height of the flare stack has been considered as 150 m. With this height, the
radiation level outside 90 m radius circle around flare stack shall be within the
allowable limits.
New Acid Gas flare shall be required for handling sour gases. Sour gases to be
flared shall be collected in a 16” pipe header connected to Acid gas KOD. Sour
gases after KOD shall be routed to flare stack of diameter 16” and height 100m with
a dedicated burning tip.
7.5.12 Effluent Treatment Plant
Cost provision for an ETP of 500 m3/hr capacity has been considered for the
selected case.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Logistics
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.6,Page 1 of 2
CHAPTER 7.6
LOGISTICS
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Logistics
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.6
Document No.
A328-RP-79-41-0002
Rev. No. 0
Chapter-7.6,Page 2 of 2
LOGISTICS
Infrastructure cost for additional crude receipt and additional product evacuation is not
required to be considered in this study. Hence, this section is excluded from the report as
per scope of work
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 1 of 26
CHAPTER 7.7
OFFSITES DESCRIPTION
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.7
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 2 of 26
OFFSITE SYSTEM
7.7.1 Storage and Transfer System
This section describes the storage and pumping facilities for feed, intermediate and finished
products based on the material balance, unit capacities, and block flow diagrams of the
refinery complex for the shortlisted refinery configurations and the selected case. Storage
capacity is based on the process unit feed/product rates, criticality of operation, emergency
operation, catalyst regeneration/replacement schedule etc.
For offsite tank calculation, following philosophy has been adopted by EIL:



In case the required no. of days (4 for crude, 5 for intermediate products and 7 for
finished products) are not available for base case at 15.0 MMTPA, storage to meet the
shortfall shall not be provided under P-25.
In case the no. of days (4 for crude, 5 for intermediate products and 7 for finished
products) are surplus for base case at 15.0 MMTPA, margin available shall be
considered for new tanks estimation for P-25.
For crude storage, separate tanks shall be considered for low sulfur and high sulfur
crudes with 4 days of storage for each.
Offsite facilities are divided into three sections
 Crude Oil storage (4 days) and transfer.
 Intermediate Feed/Intermediate Product storage (5 days) and transfer.
 Finished Product Storage (7 days).Since, product dispatch is not envisaged as part of
this study, product transfer is not established.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.7.2
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 3 of 26
Crude oil storage and transfer
Table 7.7.2.1 Refineries Tankage data of Crude Storage
Safe
filling /
Gross
Max
Tankage
holding
Tank
capacity(MT)
Stream
Capacity
No:
(MT)
301308
LBT
04
Crude
LBT
06
Dead
Stock
(MT)
Net
Holding
Capacity
(MT)
per tank
A
B
C
D=BC
336000
285600
47463
238137
34400
34400
29240
29240
5167.224
6118.9
27991.6
26885
Remarks
29767.13
13995.8
13442.5
LBT
10 &
11
68800
58480
16031.6
49358.6
24679.3
LBT
07 &
9
51600
43860
9104.992
40412.8
20206.4
#301 is used
as spare for
maintenance
and
inspection.
#302-308,
LBT 04 are
used
for
storing high
sulfur crude.
LBT 06, 07,
09,10,11 are
used
for
storing low
sulfur crude.
No new crude tanks are envisaged for this study as the existing crude oil tanks are
sufficient to provide 4 days of storage for low sulfur as well as high sulfur crude.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.7.3
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 4 of 26
Intermediate feed storage and transfer
Following points are considered while allocating storage for intermediate streams:



As per basis of study, 5 storage days have to be considered for intermediate tanks.
Intermediate unit feed flow control will be within the respective unit battery limit. No
controls are envisaged in the offsite area.
100% unit operation has been considered for new intermediate tanks.
7.7.3.1 Shortlisted Case-1
Table-7.7.3.1.1 Refineries Tankage Data of Intermediate Products/Stocks for Shortlisted
Case-1
Product
Tank No.
A
Safe filling/
Max
holding
Capacity
(MT)
B
Gross
Tankage
Capacity
(MT)
Dead
stock
(MT)
Net
holding
(MT)
C
D=B-C
DHDT Feed
403, 404,
405,406
99000
84150
13903
70247
DHDT Feed
406
16600
14110
2656
13944
502, 503, 504
54300
46155
7813
38342
901, 902
9215
7833
1744
6089
PR HGU
Feed
601, 602, 603
10350
8798
1873
6925
PRE HGU
Feed
604,605, 606
21000
17850
3037
14813
FCCU Feed
701, 702
34240
29104
4923
24181
OHCU Feed
Template No. 5-0000-0001-T2 Rev. 1
Remarks
These
tanks
have
been
utilised for the
BS-VI
DHDT
feed storage.
Tank
#502,
503, 504 will be
used
for
existing OHCU
unit
feed
storage.
Tank #901, 902
will be used for
new INDMAX
unit
feed
storage.
These
tanks
have
been
utilised in the
existing refinery
for HGU feed
storage.
Tank #701, 702
will be used for
new VGOHDT
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 5 of 26
feed storage.
Tank #402 will
be used for
existing RFCC
unit
feed
storage.
Tank #501 will
be used for new
VGOHDT feed
storage.
Tank #903 will
be used for new
INDMAX
unit
feed storage.
Two tanks will
be used to
store feed for
existing
CCR
and other two
will be used to
store feed for
new CCR.
Tank #904, 905
will be used for
existing
DCU
feed storage.
402
18100
15385
2461
12924
501
17120
14552
2461
12091
903
4750
4038
969
3069
CRU Feed
801,802,803,
804
29600
25500
4795
20705
Coker Feed
904-907
117600
99960
11780
88180
Tank #906, 907
will be used for
90% conversion
unit
feed
storage.
SLOP
Mktng. SLOP
2001-2003
71-72
11250
3200
9563
2720
1688
320
7875
2400
IFO
3001-3004
18700
15895
2805
13090
Isomerate
121
1650
1403
165
1238
Interphase
122
1650
1403
165
1238
These
tanks
have
been
retained in the
same service.
This tank will be
used to store
isomerate
produced
in
new ISOM unit.
This tank has
been retained
in the same
service.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 6 of 26
Hy. KERO
111-112
1620
1377
219
1158
MSQ NHT
Feed
304-TT-001/
304-TT-002
13600
12995
2228
10767
Isomerate
Tank ISOM.
Unit
304-TT-005
10200
9662
528
9134
These
tanks
being too small
in size have not
been utilised in
any
other
service.
Tank nos. 304TT-001
and
304-TT-002 are
sufficient
for
storing 5 day
worth of feed
for the existing
NHT unit.
This tank has
sufficient
capacity
to
store 5 day
worth
of
isomerate
for
existing ISOM
unit.

Propylene Bullets- 20 nos. of mounded bullets are required for the storage of 5 day
worth of propylene produced from the propylene recovery unit.

NHT Feed Tank- Existing tank nos. 304-TT-001 and 304-TT-002 are sufficient for
storing 5 day worth of feed for the existing NHT unit. Hence, 3 new tanks have to be
provided for the new NHT unit.

CCR Feed Tank-The 4 existing CRU feed tanks i.e. tank #801, 802, 803, 804 have
enough capacity to store 10 day worth of feed for the existing CCR. Out of the 4
existing CRU feed tanks, two are sufficient for 5 days storage of feed for existing
CCR. So, the two remaining tanks can be used for storing feed for new CCR and
they have enough capacity for 5 days storage of feed for new CCR. Hence, no new
tank for storing CCR feed is required.

Reformate Storage Tank- There is no tank for reformate storage in existing refinery.
1 new tank has to be provided in the new refinery area for reformate storage.

ISOM Feed Tank- There is no tank for ISOM feed storage in existing refinery. 1 new
tank has to be provided in the new refinery area for ISOM feed storage.

Isomerate Storage Tank- Tank #304-TT-005 has sufficient capacity to store more
than 5 day worth of isomerate for existing ISOM unit. Hence, tank#121 has been
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 7 of 26
freed up for storage of isomerate produced in new ISOM unit but it does not have
enough capacity to store 5 day worth of isomerate. So, one more tank has to be
provided to store isomerate produced from the new ISOM unit.

VGOHDT Feed Tank- Of the existing FCC feed storage tanks, tank #402 has
sufficient capacity for storage of 5 day worth of RFCC feed. Hence, tanks #501, 701
and 702 have been freed up for new VGOHDT feed storage and have sufficient
capacity for storage of 5 day worth of VGOHDT feed.

INDMAX Feed Tank- Of the existing OHCU feed storage tanks, tank #502, 503, 504
have sufficient capacity for storage of 5 day worth of OHCU feed. Hence, tanks
#901, 902 have been freed up for storage of INDMAX feed. Tank #903 currently
used to store FCC feed has also been freed up for INDMAX feed storage. But,
these three tanks together do not have sufficient capacity for storage of 5 day worth
of INDMAX feed. So, 2 new tanks also need to be provided.

INDMAX Gasoline Storage Tank- 1 new tank needs to be provided for the storage
of 5 day worth of INDMAX gasoline.

DHDT Feed Tank- 1 new tank needs to be provided for the storage of 5 day worth
of post BS-VI new DHDT feed.

Kero HDS Feed Tank- 2 new tanks need to be provided for the storage of 5 day
worth of Kero HDS feed.

90% Conversion Feed Tank- Of the 4 existing tanks used to store DCU feed, tank
#904, 905 have sufficient capacity to store 5 day worth of coker feed. Hence, tank
#906, 907 have been freed up for storage of 90% conversion unit feed and their
combined storage capacity is sufficient for storage of 5 day worth of 90% conversion
feed. So, no new tank is required for 90% conversion feed storage.
Based on the above analysis, following new intermediate storage tanks have been
considered for this case for 5 days of storage-
Table-7.7.3.1.2 Intermediate Tankages for Shortlisted Case-1
Storage
No. of Height
Dia
Type of
Tank Name
Vol/tank
Class
Tanks
(M)
(M)
Tank
(m3)
Mounded
3500
80.0
8.0
Propylene
20
GAS
Bullets
NHT feed
Reformate
Template No. 5-0000-0001-T2 Rev. 1
3
1
14.0
14.0
34.0
36.6
10164
11777
FR
CR
A
A
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Isom Feed
Isom Product
DHDT Feed
Kero HDS Feed
INDMAX Feed
INDMAX
Gasoline
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 8 of 26
1
1
1
2
2
14.0
14.0
14.4
14.4
14.2
43.0
38.8
49.1
51.5
43.5
16254
13243
21819
24006
16882
FR
FR
FR
FR
CR
A
A
B
B
C
1
14.0
36.1
11433
FR
A
The transfer pumps considered for Shortlisted Case-1 are tabulated below in table 7.7.3.1.3.
Table-7.7.3.1.3 Feed transfer pumps for Shortlisted Case-1
SERVICE
No. of
No. of RATED
OPERATING SPARE FLOW
PUMPS
PUMPS (m3/hr)
HEAD (
m)
TYPE
PPU Feed
1
1
162.0
140.1
NHT Feed
CCR Feed
Reformate
ISOM Feed
ISOM Product
DHDT Feed
KERO HDS
Feed
VGOHDT Feed
INDMAX Feed
INDMAX
Gasoline
90% CONV.
Feed
1
1
1
1
2
1
1
1
1
1
2
1
316.9
139.4
118.0
164.8
148.9
216.9
98.7
98.7
93.4
98.7
93.4
84.4
Vertical
Barrel
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Centrifugal
1
1
480.7
84.4
Centrifugal
2
2
2
2
435.5
444.8
84.4
81.5
Centrifugal
Centrifugal
1
1
114.3
93.4
Centrifugal
1
1
333.3
77.8
Centrifugal
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 9 of 26
7.7.3.2 Shortlisted Case-2
Table 7.7.3.2.1 Refineries Tankage Data of Intermediate Products/Stocks
Product
Tank No.
A
Safe filling/
Max
holding
Capacity
(MT)
B
DHDT Feed
403, 404,
405,406
99000
84150
13903
70247
DHDT Feed
406
16600
14110
2656
13944
502, 503, 504
54300
46155
7813
38342
901, 902
9215
7833
1744
6089
PR HGU
Feed
601, 602, 603
10350
8798
1873
6925
PRE HGU
Feed
604,605, 606
21000
17850
3037
14813
701, 702
34240
29104
4923
24181
402
18100
15385
2461
12924
501
17120
14552
2461
12091
903
4750
4038
969
3069
Gross
Tankage
Capacity
(MT)
Dead
stock
(MT)
Net
holding
(MT)
C
D=B-C
OHCU Feed
FCCU Feed
Template No. 5-0000-0001-T2 Rev. 1
Remarks
These
tanks
have
been
utilised for the
BS-VI
DHDT
feed storage
Tank
#502,
503, 504 will be
used
for
existing OHCU
unit
feed
storage.
Tank #901, 902
will be used for
new INDMAX
unit
feed
storage.
These
tanks
have
been
utilised in the
existing
refinery
for
HGU
feed
storage.
Tank #701, 702
will be used for
new VGOHDT
feed storage.
Tank #402 will
be used for
existing RFCC
unit
feed
storage.
Tank #501 will
be used for
new VGOHDT
feed storage.
Tank #903 will
be used for
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 10 of 26
CRU Feed
801,802,803,
804
29600
25500
4795
20705
COKER
Feed
904-907
117600
99960
11780
88180
SLOP
Mktng. SLOP
2001-2003
71-72
11250
3200
9563
2720
1688
320
7875
2400
IFO
3001-3004
18700
15895
2805
13090
Isomerate
121
1650
1403
165
1238
Interphase
122
1650
1403
165
1238
Hy. KERO
111-112
1620
1377
219
1158
MSQ NHT
Feed
304-TT-001/
304-TT-002
13600
12995
2228
10767
Template No. 5-0000-0001-T2 Rev. 1
new INDMAX
unit
feed
storage.
Two tanks will
be used to
store feed for
existing CCR
and other two
will be used to
store feed for
new CCR.
Tank #904, 905
will be used for
existing DCU
feed storage.
Tank #906, 907
will be used for
90%
conversion unit
feed storage.
These
tanks
have
been
retained in the
same service.
This tank will
be used to
store isomerate
produced
in
new ISOM unit.
This tank has
been retained
in the same
service.
These
tanks
being too small
in size have not
been utilised in
any
other
service.
Tank nos. 304TT-001
and
304-TT-002 are
sufficient
for
storing 5 day
worth of feed
for the existing
NHT unit.
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Isomerate
Tank ISOM.
Unit
304-TT-005
10200
9662
528
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 11 of 26
9134
This tank has
sufficient
capacity
to
store 5 day
worth
of
isomerate for
existing ISOM
unit.

Propylene Bullets- 20 nos. of mounded bullets are required for the storage of 5 day
worth of propylene produced from the propylene recovery unit.

NHT Feed Tank- Existing tank nos. 304-TT-001 and 304-TT-002 are sufficient for
storing 5 day worth of feed for the existing NHT unit. Hence, 3 new tanks have to be
provided for the new NHT unit.

CCR Feed Tank-The 4 existing CRU feed tanks i.e tank #801, 802, 803, 804 have
enough capacity to store 10 day worth of feed for the existing CCR. Out of the 4
existing CRU feed tanks, two are sufficient for 5 days storage of feed for existing
CCR. So, the two remaining tanks can be used for storing feed for new CCR but
they do not have enough capacity for 5 days storage of feed for new CCR. Hence, 1
new tank for storing CCR feed is required.

Reformate Storage Tank- There is no tank for reformate storage in existing refinery.
1 new tank has to be provided in the new refinery area for reformate storage.

ISOM Feed Tank- There is no tank for ISOM feed storage in existing refinery. 1 new
tank has to be provided in the new refinery area for ISOM feed storage.

Isomerate Storage Tank- Tank #304-TT-005 has sufficient capacity to store more
than 5 day worth of isomerate for existing ISOM unit. Hence, tank#121 has been
freed up for storage of isomerate produced in new ISOM unit but it does not have
enough capacity to store 5 day worth of isomerate. So, one more tank has to be
provided to store isomerate produced from the new ISOM unit.

VGOHDT Feed Tank- Of the existing FCC feed storage tanks, tank #402 has
sufficient capacity for storage of 5 day worth of RFCC feed. Hence, tanks #501, 701
and 702 have been freed up for new VGOHDT feed storage and have sufficient
capacity for storage of 5 day worth of VGOHDT feed.

INDMAX Feed Tank- Of the existing OHCU feed storage tanks, tank #502, 503, 504
have sufficient capacity for storage of 5 day worth of OHCU feed. Hence, tanks
#901, 902 have been freed up for storage of INDMAX feed. Tank #903 currently
used to store FCC feed has also been freed up for INDMAX feed storage. But,
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 12 of 26
these three tanks together do not have sufficient capacity for storage of 5 day worth
of INDMAX feed. So, 2 new tanks also need to be provided.

INDMAX Gasoline Storage Tank- 1 new tank needs to be provided for the storage
of 5 day worth of INDMAX gasoline.

DHDT Feed Tank- 1 new tank needs to be provided for the storage of 5 day worth
of post BS-VI new DHDT feed.

Kero HDS Feed Tank- 2 new tanks need to be provided for the storage of 5 day
worth of Kero HDS feed.

70% Conversion Feed Tank- Of the 4 existing tanks used to store DCU feed, tank
#904, 905 have sufficient capacity to store 5 day worth of coker feed. Hence, tank
#906, 907 have been freed up for storage of 70% conversion unit feed and their
combined storage capacity is sufficient for storage of 4.6 day worth of 70%
conversion feed. So, no new tank is required for 70% conversion feed storage.
Based on the above analysis, following new intermediate storage tanks have been considered for
this case for 5 days of storage:
Table 7.7.3.2.2 Intermediate Tankages for Shortlisted Case-2
Tank
Propylene
NHT feed
CCR Feed
Reformate
Isom Feed
Isom Product
DHDT Feed
Kero HDS Feed
INDMAX Feed
INDMAX
Gasoline
No of
Tanks
Height
(M)
Dia
(M)
Storage
Vol /tank
(m3)
20
80.0
8.0
3
1
1
1
1
1
2
2
14.0
14.0
14.0
14.0
14.0
14.4
14.4
14.2
1
14.0
Type of
Tank
Class
3500
Mounded
Bullets
GAS
35.8
15.3
40.8
42.8
38.7
50.0
51.5
44.0
11268
2045
14620
16134
13136
22651
24006
17286
FR
CFR
CR
FR
FR
FR
FR
CR
A
A
A
A
A
B
B
C
36.4
11633
FR
A
The transfer pumps considered for Shortlisted Case-2 are tabulated below in table 7.7.3.2.3.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 13 of 26
Table 7.7.3.2.3 Feed transfer pumps for Shortlisted Case-2
SERVICE
No. of
OPERATING
PUMPS
No. of
SPARE
PUMPS
RATED
FLOW
(m3/hr)
HEAD ( m)
TYPE
PPU Feed
1
1
165.0
140.1
Vertical Barrel
NHT Feed
1
1
338.0
98.7
Centrifugal
CCR Feed
2
2
173.2
98.7
Centrifugal
Reformate
1
1
146.2
93.4
Centrifugal
ISOM Feed
1
1
160.6
98.7
Centrifugal
ISOM Product
2
2
147.9
93.4
Centrifugal
DHDT Feed
1
1
225.9
84.4
Centrifugal
KERO HDS Feed
1
1
480.7
84.4
Centrifugal
VGOHDT Feed
2
2
435.5
84.4
Centrifugal
INDMAX Feed
2
2
453.5
81.5
Centrifugal
INDMAX Gasoline
1
1
116.3
93.4
Centrifugal
70% CONV. Feed
1
1
533.3
77.8
Centrifugal
7.7.3.3 Selected case
Table 7.7.3.3.1 Refineries Tankage data of Intermediate products/stocks
Product
Tank No.
Gross
Tankage
Capacity
(MT)
Safe filling/
Max
holding
Capacity
(MT)
Dead
stock
(MT)
Net
holding
(MT)
A
B
C
D=BC
DHDT Feed
403, 404, 405
99000
84150
13903
70247
DHDT Feed
406
16600
14110
2656
13944
OHCU Feed
502, 503, 504
54300
46155
7813
38342
Template No. 5-0000-0001-T2 Rev. 1
Remarks
These
tanks
have
been
utilised for the
BS-VI
DHDT
feed storage.
Tank
#502,
503, 504 will be
used
for
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 14 of 26
901, 902
9215
7833
1744
6089
PR HGU
Feed
601, 602, 603
10350
8798
1873
6925
PRE HGU
Feed
604,605, 606
21000
17850
3037
14813
701, 702
34240
29104
4923
24181
402
18100
15385
2461
12924
501
17120
14552
2461
12091
903
4750
4038
969
3069
CRU Feed
801,802,803,
804
29600
25500
4795
20705
Coker Feed
904-907
117600
99960
11780
88180
FCCU Feed
existing OHCU
unit
feed
storage.
Tank #901, 902
will be used for
new INDMAX
unit
feed
storage.
These
tanks
have
been
utilised in the
existing refinery
for HGU feed
storage.
Tank #701, 702
will be used for
new VGOHDT
feed storage.
Tank #402 will
be used for
existing RFCC
unit
feed
storage.
Tank #501 will
be used for new
VGOHDT feed
storage.
Tank #903 will
be used for new
INDMAX
unit
feed storage.
Two tanks will
be used to
store feed for
existing
CCR
and other two
will be used to
store feed for
new CCR.
Tank #904, 905
will be used for
existing
DCU
feed storage.
Tank #906, 907
will be used for
70% conversion
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 15 of 26
7875
SLOP
Mktng. SLOP
IFO
2001-2003
71-72
3001-3004
11250
3200
18700
9563
2720
15895
1688
320
2805
2400
13090
Isomerate
121
1650
1403
165
1238
Interphase
122
1650
1403
165
1238
Hy. KERO
111-112
1620
1377
219
1158
MSQ NHT
Feed
304-TT-001/
304-TT-002
13600
12995
2228
10767
Isomerate
Tank ISOM.
Unit
304-TT-005
10200
9662
528
9134
unit
feed
storage.
These
tanks
have
been
retained in the
same service.
This tank will be
used to store
isomerate
produced
in
new ISOM unit.
This tank has
been retained
in the same
service.
These
tanks
being too small
in size have not
been utilised in
any
other
service.
Tank nos. 304TT-001
and
304-TT-002 are
sufficient
for
storing 5 day
worth of feed
for the existing
NHT unit.
This tank has
sufficient
capacity
to
store 5 day
worth
of
isomerate
for
existing ISOM
unit.

Propylene Bullets- 7 nos. of mounded bullets are required for the storage of 5 day
worth of propylene produced from the propylene recovery unit.

NHT Feed Tank- Existing tank nos. 304-TT-001 and 304-TT-002 are sufficient for
storing 5 day worth of feed for the existing NHT unit. Hence, 2 new tanks have to be
provided for the new NHT unit.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 16 of 26

CCR Feed Tank-The 4 existing CRU feed tanks i.e tank #801, 802, 803, 804 have
enough capacity to store 10 day worth of feed for the existing CCR. Out of the 4
existing CRU feed tanks, two are sufficient for 5 days storage of feed for existing
CCR. So, the two remaining tanks can be used for storing feed for new CCR and
they have enough capacity for 5 days storage of feed for new CCR. Hence, no new
tank for storing CCR feed is required.

Reformate Storage Tank- There is no tank for reformate storage in existing refinery.
1 new tank has to be provided in the new refinery area for reformate storage.

ISOM Feed Tank- There is no tank for ISOM feed storage in existing refinery. 1 new
tank has to be provided in the new refinery area for ISOM feed storage.

Isomerate Storage Tank- Tank #304-TT-005 has sufficient capacity to store more
than 5 day worth of isomerate for existing ISOM unit. Hence, tank#121 has been
freed up for storage of isomerate produced in new ISOM unit but it does not have
enough capacity to store 5 day worth of isomerate. So, one more tank has to be
provided to store isomerate produced from the new ISOM unit.

VGOHDT Feed Tank- Of the existing FCC feed storage tanks, tank #402 has
sufficient capacity for storage of 5 day worth of RFCC feed. Hence, tanks #501, 701
and 702 have been freed up for new VGOHDT feed storage and have sufficient
capacity for storage of 5 day worth of VGOHDT feed.

INDMAX Feed Tank- Of the existing OHCU feed storage tanks, tank #502, 503, 504
have sufficient capacity for storage of 5 day worth of OHCU feed. Hence, tanks
#901, 902 have been freed up for storage of INDMAX feed. Tank #903 currently
used to store FCC feed has also been freed up for INDMAX feed storage. But,
these three tanks together do not have sufficient capacity for storage of 5 day worth
of INDMAX feed. So, 2 new tanks also need to be provided.

INDMAX Gasoline Storage Tank- 1 new tank needs to be provided for the storage
of 5 day worth of INDMAX gasoline.

DHDT Feed Tank- 1 new tank needs to be provided for the storage of 5 day worth
of post BS-VI new DHDT feed.

Kero HDS Feed Tank- 2 new tanks need to be provided for the storage of 5 day
worth of Kero HDS feed.

70% Conversion Feed Tank- Of the 4 existing tanks used to store DCU feed, tank
#904, 905 have sufficient capacity to store 5 day worth of coker feed. Hence, tank
#906, 907 have been freed up for storage of 70% conversion unit feed and their
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 17 of 26
combined storage capacity is sufficient for storage of 5 day worth of 70% conversion
feed. So, no new tank is required for 70% conversion feed storage.
Based on the above analysis, following new intermediate storage tanks have been considered for
this case for 5 days of storage-
Table 7.7.3.3.2 Intermediate Tankages for Selected Case
Tank Name
Propylene
NHT feed
Reformate
Isom Feed
Isom Product
DHDT Feed
Kero HDS Feed
INDMAX Feed
INDMAX Gasoline
Alkylate Feed
Alkylate Product
Fresh Acid
Spent Acid
No. of Tanks Height (M) Dia (M)
7
2
1
1
1
1
2
2
1
1
1
1
2
80.0
14.0
14.0
10.0
11.0
14.4
14.4
14.2
14.0
80
14
10
10
8.0
31.6
35.6
26.2
18.0
35.1
51.5
39.5
33.6
8
38
8
6
Storage Vol /tank
(m3)
Type of Tank
Class
3215
8779
11143
4296
2243
11141
24006
13928
9940
3215
12550
434
228
Mounded Bullets
FR
CR
FR
FR
FR
FR
CR
FR
Mounded Bullets
FR
CR
CR
GAS
A
A
A
A
B
B
C
A
GAS
A
C
C
The transfer pumps considered for Selected Case are tabulated below in table 7.7.3.3.3.
Table 7.7.3.3.3 Feed transfer pumps for Selected case
SERVICE
No. of
OPERATING
PUMPS
No. of
SPARE
PUMPS
RATED FLOW
(m3/hr)
HEAD
(m)
TYPE
PPU Feed
NHT Feed
CCR Feed
REFORMATE
1
1
1
1
1
1
1
1
135.0
175.5
131.8
111.5
140.1
98.7
98.7
93.4
Vertical Barrel
Centrifugal
Centrifugal
Centrifugal
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
ISOM Feed
ISOM PRODUCT
DHDT Feed
KERO HDS Feed
VGOHDT Feed
INDMAX Feed
INDMAX Gasoline
70% CONV. Feed
Alkylate Product
Fresh Acid
Spent Acid
7.7.4
1
2
1
1
2
2
1
1
1
1
1
1
2
1
1
2
2
1
1
1
1
1
43.0
38.9
125.4
480.1
402.5
385.1
99.4
475.6
125.5
5.4
5.7
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 18 of 26
98.7
93.4
84.4
84.4
84.4
81.5
93.4
77.8
87.6
38.1
38.1
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Centrifugal
Finished Product Storage and Transfer Philosophy
As per the basis of study, minimum 7 days shall be available for storage of each product. Hence
new storage tanks for LPG, Naphtha, MS and Diesel are considered.
7.7.4.1 Finished Product Tankages for Shortlisted Case-1
Details of the existing product storage facilities are given below:
Product
LPG
Table 7.7.4.1.1 Existing Product storage facilities
Safe
Gross
filling/
Dead
Net
Tankage
Max
stock holding
Capacity holding
(MT)
(MT)
Tank No.
Remarks
(MT)
Capacity
(MT)
D=BA
B
C
C
These spheres are
used for the
HS 1 – 7
5838
5254
117
5137
storage of LPG
produced in the
base case.
These bullets are
used
for
the
BULLET-1 & 2
3114
2802
183
2619
storage of LPG
produced in the
base case.
These bullets are
BULLET-3 & 4
2929
2636
161
2475
used
for
the
storage of LPG
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 19 of 26
produced in
base case.
MS
21-24
16
25-26
11,12,13
15
44100
14700
14903
10575
14100
37485
12495
12667
8989
11985
6732
2414
1895
2249
2381
30753
10081
10772
6740
9604
401
14100
11985
2162
9823
51,52,53,54
64000
54400
9101
45299
31,32,33,34,35
60000
51000
10809
40191
Naphtha
SKO
the
These tanks are
retained in MS
service.
These tanks will be
used
to
store
naphtha produced
in the existing as
well
as
new
refinery.
Since, there will be
no SKO production
in Shortlisted Case1, these tanks will
be used for storage
of
incremental
production of diesel
in Shortlisted Case1.
Tank #31, 32, 33 &
34 will be used for
storage of ATF
produced
in
Shortlisted Case-1.
ATF
36
16600
14110
2656
13944
HSD-III
61,62,64,65,66
165000
140250
22559
117691
HSD-IV
63, 67-68
99000
84150
13969
70181
FO
81,82,83,84
19000
16150
2040
14110
91-93
14250
12113
1591
10521
94 - 99
29400
24990
3182
21808
Bitumen

Tank #35, 36 will
be used for storage
of
incremental
production of diesel
in Shortlisted Case1.
These tanks are
retained in diesel
service.
These tanks are
retained
in
the
same service.
These tanks are
retained
in
the
same service.
LPG - The LPG storage facilities present in the existing refinery have capacity to store only
around 5 day worth of LPG produced in the base case. So, 16 new mounded bullets are
required for the storage of incremental LPG produced in Shortlisted Case-1.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 20 of 26

Naphtha- The existing naphtha tanks are not adequate to store 7 day worth of naphtha
produced in the study Shortlisted Case-1. So, 1 new tank for storing naphtha needs to be
provided.

Regular MS- The existing MS tanks have sufficient storage capacity to store around 10 day
worth of regular MS produced in the base case. So, some storage space in the existing
tanks can be utilised to store incremental production of MS in Shortlisted Case-1.Still, 3
new tanks would be required to have sufficient storage capacity for 7 day worth of
incremental MS production.

Premium MS- There is no storage tank for premium MS in existing refinery. So, 1 new tank
will be required to store premium MS produced in shortlisted case-1.

ATF- Of the 6 existing tanks in ATF service, tank #31, 32, 33 & 34 have sufficient capacity
for storage of 7 day worth of ATF produced in Shortlisted Case-1. Tank #35 & 36 currently
in ATF service have been freed up for storage of incremental diesel production in
Shortlisted Case-1.

Diesel- The existing HSD storage tanks have capacity to store around 8 day worth of diesel
produced in base case. So, some storage space in the existing tanks can be utilised to
store incremental production of diesel in Shortlisted Case-1. Tank #35 & 36 currently in
ATF service and tank #51-54 currently in SKO service have been freed up for storage of
incremental diesel production in Shortlisted Case-1. Still, 1 new tank is required to have
sufficient storage capacity for storing 7 day worth of incremental diesel production in
Shortlisted Case-1.
Based on the above analysis, following new product storage tanks have been considered for this
case for 7 days of storageTable 7.6.9 Product Tankages for Shortlisted Case-1
Tank No.s
No of
Tanks
Height
(M)
Dia
(M)
Storage Vol
/tank
(m3)
Type of
Tank
Class
LPG
16
70
7
2154
Mounded
Bullets
GAS
Naphtha
Regular MS
Premium MS
Diesel
Polypropylene
1
14.2
40.7
14772
FR
A
3
13.4
39.9
13397
FR
A
1
14.4
30.7
8523
FR
A
1
14.4
43.1
16799
FR
B
Pelletizer and storage facility for 11340 pellets (1 pellet is for 1 ton of
polypropylene).
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 21 of 26
7.7.4.2 Finished Product Tankages for Shortlisted Case-2
Product
Table 7.7.4.2.1 Existing Product storage facilities
Safe
Gross
filling/
Dead
Net
Tankage
Max
stock holding
Capacity holding
(MT)
(MT)
Tank No.
(MT)
Capacity
(MT)
D=BA
B
C
C
HS 1 – 7
5838
5254
117
5137
BULLET-1 & 2
3114
2802
183
2619
BULLET-3 & 4
2929
2636
161
2475
21-24
16
25-26
44100
14700
14903
37485
12495
12667
6732
2414
1895
30753
10081
10772
11,12,13
10575
8989
2249
6740
15
14100
11985
2381
9604
401
14100
11985
2162
9823
51,52,53,54
64000
54400
9101
45299
LPG
MS
Naphtha
SKO
Template No. 5-0000-0001-T2 Rev. 1
Remarks
These spheres are
used for the
storage of LPG
produced in the
base case.
These bullets are
used
for
the
storage of LPG
produced in the
base case.
These tanks are
retained in MS
service.
These tanks will
be used to store
naphtha produced
in the existing as
well
as
new
refinery.
Since, there will
be
no
SKO
production
in
Shortlisted Case2, these tanks will
be
used
for
storage
of
incremental
production
of
diesel
in
Shortlisted Case2.
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
31,32,33,34,35
60000
51000
10809
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 22 of 26
40191
ATF
36
16600
14110
2656
13944
HSD-III
61,62,64,65,66
165000
140250
22559
117691
HSD-IV
63, 67-68
99000
84150
13969
70181
FO
81,82,83,84
19000
16150
2040
14110
91-93
14250
12113
1591
10521
94 - 99
29400
24990
3182
21808
Bitumen
Tank #31, 32, 33
& 34 will be used
for storage of ATF
produced
in
Shortlisted Case2.
Tank #35, 36 will
be
used
for
storage
of
incremental
production
of
diesel
in
Shortlisted Case2.
These tanks are
retained in the
same service.
These tanks are
retained in the
same service.
These tanks are
retained in the
same service.

LPG - The LPG storage facilities present in the existing refinery have capacity to store only
around 5 day worth of LPG produced in the base case. So, 16 new mounded bullets are
required for the storage of incremental LPG produced in Shortlisted Case-2.

Naphtha- The existing naphtha tanks are not adequate to store 7 day worth of naphtha
produced in the study Shortlisted Case-2. So, 1 new tank for storing naphtha needs to be
provided.

MS- The existing MS tanks have sufficient storage capacity to store around 10 day worth of
MS produced in the base case. So, some storage space in the existing tanks can be
utilised to store incremental production of regular MS in Shortlisted Case-2.Still, 3 new
tanks would be required to have sufficient storage capacity for 7 day worth of incremental
MS production.
Premium MS- There is no storage tank for premium MS in existing refinery. So, 1 new tank
will be required to store premium MS produced in shortlisted case-2.


ATF- Of the 6 existing tanks in ATF service, tank #31, 32, 33 & 34 have sufficient capacity
for storage of 7 day worth of ATF produced in Shortlisted Case-2. Tank #35 & 36 currently
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 23 of 26
in ATF service have been freed up for storage of incremental diesel production in
Shortlisted Case-2.

Diesel- The existing HSD storage tanks have capacity to store around 8 day worth of diesel
produced in base case. So, some storage space in the existing tanks can be utilised to
store incremental production of diesel in Shortlisted Case-2. Tank #35 & 36 currently in
ATF service and tank #51-54 currently in SKO service have been freed up for storage of
incremental diesel production in Shortlisted Case-2. Still, 1 new tank is required to have
sufficient storage capacity for storing 7 day worth of incremental diesel production in
Shortlisted Case-2.
Based on the above analysis, following new product storage tanks have been considered for this
case for 7 days of storageTable 7.7.4.2.2 Product Tankages for Shortlisted Case-2
No of
Tanks
Tank Nos.
LPG
Polypropylene
Dia
(M)
Storage
Vol/tank
(m3)
Type of
Tank
Class
Mounded
Gas
Bullets
1
14.2
40.7
14772
FR
A
3
13.4
38.9
12734
FR
A
1
14.4
41.8
15801
FR
A
1
14.4
50.8
23337
FR
B
Pelletizer and storage facility for 11550 pellets (1 pellet is for 1 ton
of polypropylene).
16
Naphtha
Regular MS
Premium MS
Diesel
Height
(M)
70
7
2154
7.7.4.3 Finished Product Tankages for Selected Case
Details of the existing product storage facilities are given below:
Product
LPG
Table 7.7.4.3.1 Existing Product Storage Facilities
Safe
Gross
filling/
Dead
Net
Tankage
Max
stock holding
Capacity holding
(MT)
(MT)
Tank No.
Remarks
(MT)
Capacity
(MT)
D=BA
B
C
C
These spheres are
HS 1 – 7
5838
5254
117
5137
used for the
storage of LPG
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
MS
Naphtha
SKO
BULLET-1 & 2
3114
2802
183
2619
BULLET-3 & 4
2929
2636
161
2475
21-24
16
25-26
44100
14700
14903
37485
12495
12667
6732
2414
1895
30753
10081
10772
11,12,13
10575
8989
2249
6740
15
14100
11985
2381
9604
401
14100
11985
2162
9823
51,52,53,54
64000
54400
9101
45299
31,32,33,34,35
60000
51000
10809
40191
ATF
36
16600
14110
2656
13944
HSD-III
61,62,64,65,66
165000
140250
22559
117691
HSD-IV
63, 67-68
99000
84150
13969
70181
FO
81,82,83,84
19000
16150
2040
14110
Bitumen
91-93
94 - 99
14250
29400
12113
24990
1591
3182
10521
21808
Template No. 5-0000-0001-T2 Rev. 1
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 24 of 26
produced in the
base case.
These bullets are
used
for
the
storage of LPG
produced in the
base case.
These bullets are
used
for
the
storage of LPG
produced in the
base case.
These tanks are
retained in MS
service.
These tanks will be
used
to store naphtha
produced in the
existing as well as
new refinery.
Since, there will be
no SKO production
in Selected case,
these tanks will be
used for storage of
incremental
production of diesel
in Selected Case.
Tank #31, 32, 33 &
34 will be used for
storage of ATF
produced
in
Selected Case.
Tank #35, 36 will
be used for storage
of
incremental
production of diesel
in Selected Case.
These tanks are
retained in diesel
service.
These tanks are
retained
in
the
same service.
These tanks are
retained
in
the
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 25 of 26
same service.

LPG - The LPG storage facilities present in the existing refinery have capacity to store only
around 5 day worth of LPG produced in the base case. So, 1 new mounded bullet is
required for the storage of incremental LPG produced in Selected Case.

Naphtha- The existing naphtha tanks are not adequate to store 7 day worth of naphtha
produced in the study Selected Case. So, 1 new tank for storing naphtha needs to be
provided.

MS- The existing MS tanks have sufficient storage capacity to store around 10 day worth of
MS produced in the base case. Tank #21 has sufficient capacity to store 7 day worth of
regular MS production in Selected Case and tanks #16,22,23,24,25,26 can be utilised for
storing premium MS produced in Selected case. Still, 3 new tanks would be required to
have sufficient storage capacity for 7 day worth of incremental premium MS production.

ATF- Of the 6 existing tanks in ATF service, tank #31, 32, 33, 34 & 36 have sufficient
capacity for storage of 7 day worth of ATF produced in Selected Case. Tank #35 currently
in ATF service has been freed up for storage of incremental diesel production in Selected
Case.

Diesel- The existing HSD storage tanks have capacity to store around 8 day worth of diesel
produced in base case. So, some storage space in the existing tanks can be utilised to
store incremental production of diesel in Shortlisted Case-1. Tank #35 currently in ATF
service and tank #51-54 currently in SKO service have been freed up for storage of
incremental diesel production in Selected Case. Still, 1 new tank is required to have
sufficient storage capacity for storing 7 day worth of incremental diesel production in
Selected Case.
Based on the above analysis, following new product storage tanks have been considered for this
case for 7 days of storage-
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Offsite Description
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-002
Rev. No. 0
Chapter-7.7,Page 26 of 26
Table 7.7.4.3.2 Product Tankages for Selected Case
Tank No.s
LPG
Naphtha
MS
(PREMIUM)
DIESEL
POLY
PROPYLENE
No of
Tanks
1
1
Height (M)
80
16.0
Dia (M)
8
45.1
Storage Vol
/tank
(m3)
3215
20438
Type of Tank
Class
Mounded
Bullets
FR
GAS
A
3
13.4
39.7
13263
FR
A
1
14.4
59.6
32123
FR
B
PELLETIZER AND STORAGE FACILITY FOR 9450 PELLETS (1 PELLET IS
FOR 1 TON OF POLYPROPYLENE)
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Sulfur Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.8,Page 1 of 6
CHAPTER 7.8
SULFUR BALANCE
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.8,Page 2 of 6
Sulfur Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.8
SULFUR BALANCE
This section provides the sulfur balance for the refinery.
Table 7.8.1 Existing SRU capacity
Capacity
Design capacity
considered for
(TPD)
the study
(TPD)
Description
SRU PR
230
115
SRU PREP+PRAEP
675
450
SRU BS-VI
225
225
Total SRU Capacity
1130
790
Remarks
Common incinerator
allows only one SRU
train to operate.
Considering 1 train
as spare.
No spare.
7.8.1 Shortlisted Cases
The two shortlisted cases considered for the Panipat refinery expansion were:
Table 7.8.2 Shortlisted cases
Shortlisted Case-1
Shortlisted Case-2
90% CONV + VGOHDT +
INDMAX LOW CCR + PRU +
PPU
70% CONV + VGOHDT +
INDMAX LOW CCR + PRU
+ PPU
The sulphur content of crude considered for the shortlisted cases is 1.8 wt %.
7.8.2
Sulphur Balance of Shortlisted Case - 1
The sulphur balance of Shortlisted case -1 is presented below in table 7.8.2
Table 7.8.2.1 Sulfur balance of Shortlisted Case - 1
Feed Stream
Sulphur (ppmw)
Feed in TPD
Sulphur (TPD)
CRUDE BLEND
18268
RLNG
30
75000.0
4744.0
1370.09
0.1
C7-C8 FROM PNCP
C9+ STREAM FROM PNCP
0.1
250
684.0
300.0
0.00
0.08
FUEL OIL FROM PNCP
C4 FROM PNCP
C5 FROM PNCP
SURPLUS H2 AVAILABLE
400
0
0
0
336.0
600.0
510.0
20.0
0.13
0.00
0.00
0.00
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.8,Page 3 of 6
Sulfur Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
MATHURA REF. NAPHTHA
Total Feed Sulfur
500
Products Stream
Sulphur (ppmw)
MIXED LPG'S
5
RFCC PROPYLENE
POLYMER GRADE PROPYLENE
FUEL GAS FROM RFCC AND DCU
PREMIUM GASOLINE
0
0
30
BS-VI REG. GASOLINE
8
BENZENE
PTA
TOTAL NAPHTHA TO PNCP
450.0
Products in
TPD
4704
0.23
1370.6
Sulphur (TPD)
0.02
248
917
0.00
0.00
0.01
0.01
11687
0.09
0
0
500
5238
0.00
0.00
2.62
ATF
1419.22
4500
6.39
BS-VI HSD
8
38534
0.31
BITUMEN
DCU COKE
55000
1080
BHU PITCH
59.40
136.37
13.68
Total Sulfur in products
218.90
8
8.68
Total Sulfur as Refinery SOx
Total Sulfur in Feed, TPD
Total Sulfur in Products, TPD
Total Sulfur in Refinery SOx, TPD
Sulfur Capacity in terms of Sulfur Product, TPD
SRU PR
SRU PREP+PRAEP
SRU BS-VI
Total SRU Capacity available, TPD
New SRU Capacity Required, TPD
No. of trains
Each train capacity (TPD)
Template No. 5-0000-0001-T2 Rev. 1
1370.6
218.90
8.68
1143.02
115
450
225
790
354
2
177
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.8,Page 4 of 6
Sulfur Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.8.3 Sulphur Balance of Shortlisted Case - 2
The sulphur balance of Shortlisted Case – 2 is presented below in Table 7.8.3
Table 7.8.3.1 Sulfur balance of Shortlisted case - 2
Feed Stream
CRUDE BLEND
RLNG
C7-C8 FROM PNCP
C9+ STREAM FROM PNCP
FUEL OIL FROM PNCP
C4 FROM PNCP
C5 FROM PNCP
SURPLUS H2 AVAILABLE
MATHURA REF. NAPHTHA
Total Feed Sulfur
Products Stream
MIXED LPG'S
RFCC PROPYLENE
POLYMER GRADE PROPYLENE
FUEL GAS FROM RFCC AND DCU
BS-VI PREMIUM GASOLINE
BS-VI REG. GASOLINE
BENZENE
PTA
TOTAL NAPHTHA TO PNCP
ATF
BS-VI HSD
BITUMEN
DCU COKE
Total Sulfur in products
Total Sulfur as Refinery SOx
Sulphur
(ppmw)
Feed in TPD
Sulphur (TPD)
18268
30
0.1
250
400
0
0
0
500
75000.0
5,833
684.0
300.0
336.0
600.0
510.0
20.0
450.0
1370.09
0.2
0.00
0.08
0.13
0.00
0.00
0.00
0.23
1370.73
Products in TPD
Sulphur (TPD)
4549
0.02
0.00
0.00
0.01
0.01
0.11
0.00
0.00
2.62
6.39
0.32
59.40
104.27
173.15
5.33
Sulphur
(ppmw)
5
0
0
30
8
8
0
0
500
1420.1
8
55000.0
Total Sulfur in Feed, TPD
Total Sulfur in Products, TPD
Total Sulfur in Refinery SOx, TPD
Sulfur Capacity in terms of Sulfur Product, TPD
SRU PR
SRU PREP+PRAEP
Template No. 5-0000-0001-T2 Rev. 1
252
1696
11482
5238
4500
39452
1080
1370.73
173.15
5.33
1192.25
115
450
Copyright EIL – All rights reserved
Sulfur Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.8,Page 5 of 6
SRU BS-VI
Total SRU Capacity available, TPD
New SRU Capacity Required, TPD
No. of trains
Each train capacity (TPD)
225
790
403
2
201
7.8.4 Selected case
The selected case of the Panipat Configuration study is as follows:
Table 7.8.4.1: Selected Case
Selected Case
70% CONV + VGOHDT + INDMAX LOW CCR + PPU ( 450
KTPA) + ALKYLATION UNIT
For the selected case it was proposed to have adequate margin in the SRU capacity
considering higher sulfur content of crude (2.2 wt. % instead of 1.8 wt. %).
7.8.5 Sulphur balance of the selected case
The sulphur balance of the selected case is as follows in Table 7.8.4.1:
Table 7.8.5.1: Sulphur balance of the selected case
CRUDE BLEND
RLNG
C7-C8 FROM PNCP
C9+ STREAM FROM PNCP
22000
30
0.2
250
Feed in
TPD
75000.0
4343.0
684.0
300.0
FUEL OIL FROM PNCP
400
336.0
0.1
C4 FROM PNCP
C5 FROM PNCP
SURPLUS H2 AVAILABLE
MATHURA REF. NAPHTHA
TOTAL FEED SULFUR
0
0
0
500
600.0
510.0
20.0
450.0
0.0
0.0
0.0
0.2
1650.56
Products Stream
Sulphur (ppmw)
MIXED LPG'S
RFCC PROPYLENE
POLY PROPYLENE
0.85
0
0
Feed Stream
Template No. 5-0000-0001-T2 Rev. 1
Sulphur (ppmw)
Sulphur (TPD)
1650.0
0.1
0.0
0.1
Products
Sulphur (TPD)
in TPD
2176
332
1350
0.00
0.00
0.00
Copyright EIL – All rights reserved
Sulfur Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
POLYMER GRADE PROPYLENE
FUEL GAS FROM RFCC AND DCU
E-VI REGULAR GASOLINE
PREMIUM GASOLINE
BENZENE
PTA
TOTAL NAPHTHA TO PNCP
ATF
BS VI SULFUR DIESEL
BITUMEN
DCU COKE
0
30
8
8
0
0
500
1067.1587
8
46053.4492
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.8,Page 6 of 6
0
254
10546
854
74
2100
8208
6000
38270
1080
0.00
0.01
0.08
0.01
0.00
0.00
4.10
6.40
0.31
49.74
138.84
Total product sulfur
199.49
Total Sulfur as Refinery SOx
13.09
Total Sulfur in Feed, TPD
1650.56
Total Sulfur in Products, TPD
199.49
13.09
Total Sulfur in Refinery SOx, TPD
Sulfur Capacity in terms of Sulfur Product, TPD
SRU PR
SRU PREP+PRAEP
SRU BS-VI
Total SRU Capacity available, TPD
New SRU capacity required, TPD
No. of trains
Each train capacity (TPD)
7.8.6
1437.98
115
450
225
790
648
2
324
Inferences
The capacity of new Sulphur recovery unit is 2x324 TPD.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Hydrogen Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.9,Page 1 of 6
CHAPTER 7.9
HYDROGEN BALANCE
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.9,Page 2 of 6
Hydrogen Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
7.9 HYDROGEN BALANCE
This chapter describes the overall refinery hydrogen balance.
Main consumers of hydrogen in the refinery are hydrocrackers, isomerization unit,
Prime-G and DHDT. Also, amongst the new envisaged units, isomerization unit,
Kerosene hydro-desulfurization unit, DHDT and bottom processing units are major
consumers of hydrogen.
Hydrogen will be available form Hydrogen generation units, CCR PSA’s and PNCP.
7.9.1 Hydrogen Balance
The two shortlisted cases considered for the Panipat refinery expansion are:
Table 7.9.1.1 Existing SRU capacity
Shortlisted Case-1
Shortlisted Case-2
90% CONV + VGOHDT +
INDMAX LOW CCR + PRU +
PPU
70% CONV + VGOHDT +
INDMAX LOW CCR + PRU
+ PPU
The hydrogen balance for shortlisted cases is presented in the table 7.9.1.2.
Table 7.9.1.2 Hydrogen Balance for Shortlisted Cases
Hydrogen Consumption (KTPA)
Process Units
Shortlisted Case - 1
Shortlisted Case - 2
LT NAPHTHA HDT
0.3
0.3
ISOM
2.7
2.7
PRIME G
2.7
2.7
PR DHDT
5.3
5.3
PREP DHDT
40.3
40.3
BS-VI DHDT
14.7
15
PR OHCU
51.7
51.7
PREP FC-HCU
42
42
Sub Total
159.7
160
0.3
0.3
Existing Refinery Units
New Units
PPU
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Hydrogen Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.9,Page 3 of 6
NEW NHT
1.3
1.7
ISOM
8.3
8.3
KERO HDS
16
16
DHDT
25.3
25.3
VGOHDT
30.7
30.7
90% CONV
69
-
70% CONV
-
94.7
Sub Total
150.9
177
Total Consumption
310.6
337
Hydrogen Production (KTPA)
Existing Refinery Units
PR HGU
PREP HGU
36
38
133
131.7
BS-VI HGU
41.7
41.3
CCR PSA
10.7
10.7
PSA (FOR DHDT AND HCU)
3
3
AROMATIC COMPLEX
22.3
22.3
PNCP
6.7
6.7
Sub Total
253.4
253.7
Sub Total assuming existing
HGUs operating at 90%
capacity
242.5
242.5
PSA (FOR CCR, DHDT AND
90% CONVERSION)
24.3
28.3
Sub Total
24.3
28.3
Total Production
277.7
282
Total Production assuming
HGUs operating at 90%
capacity
266.8
270.8
New Units
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.9,Page 4 of 6
Hydrogen Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
New HGU
New HGU (assuming
existing HGUs operating at
90% capacity)
45
67
7.9.2 Hydrogen Balance for the selected case
The selected case for this configuration study is:
Table 7.9.2.1 : Selected Case
Selected Case
70% CONV + VGOHDT + INDMAX LOW CCR + PPU ( 450
KTPA) + ALKYLATION UNIT
The hydrogen balance for the selected case is as follows:
Table 7.9.2.2: Hydrogen balance for the selected case
Hydrogen Consumption (KTPA)
Process Units
Selected Case
Existing Refinery Units
LT NAPHTHA HDT
0.7
ISOM
2.7
PRIME G
2.7
PR DHDT
5.3
PREP DHDT
42.3
BS-VI DHDT
26.7
PR OHCU
54.3
PREP FC-HCU
44.0
178.7
Sub Total
New Units under P-25
PPU
Template No. 5-0000-0001-T2 Rev. 1
0.3
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.9,Page 5 of 6
Hydrogen Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
NEW NHT
1.0
ISOM
2.3
KERO HDS
16.0
DHDT
8.3
VGOHDT
28.0
70% CONV.
82.0
Sub Total
138.0
Total Consumption
316.7
Hydrogen Production (KTPA)
Existing Refinery Units
PR HGU
PREP HGU
BS-VI HGU
CCR PSA
PSA (FOR DHDT AND HCU)
38.0
131.7
44.0
10.7
3.3
AROMATIC COMPLEX
22.3
PNCP
0
Sub Total
New Units under P-25
PSA (FOR CCR, DHDT AND 90%
CONVERSION)
256.7
21.3
Sub Total
21.3
Total Production
278.0
Total Production assuming HGUs
operating at 90% capacity
New HGU
New HGU (assuming existing HGUs
operating at 90% capacity and for the
higher sulphur content of crude i.e. 2.2
wt.%) )
Template No. 5-0000-0001-T2 Rev. 1
264.1
65
Copyright EIL – All rights reserved
Hydrogen Balance
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 7.9,Page 6 of 6
7.9.3 Inferences
New HGU capacity required for the selected case is 65 KTPA.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 1 of 22
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
CHAPTER 8
ENVIRONMENTAL CONSIDERATIONS
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
8.0
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 2 of 22
Environment consideration
Introduction
Industrial development is essential for growth and betterment of the living conditions of the
society. Industrial development, however, is endemic with its effect on the environment. It is
essential that even while the industrial development is spurred for growth, the environment is
conserved and protected. The proposed expansion project from 15.0 MMTPA to 25.0 MMTPA
is a step in the direction of spurring industrial activity. Notwithstanding this fact, it has been
considered essential to adopt environmental protection measures and adhere to legislations
such that the ecology and the habitat of the area are not disturbed.
Various pollution control measures required to meet the prevailing environmental standards are
planned at the different stages of execution of the project, viz., design, construction and
operational phases.
The quality and quantity of effluent considered in this section are preliminary estimates based
on in-house data and are required to be confirmed during design stage,
8.1
Indian Environmental Legislation
Government of India has made many legislations/rules for the protection and improvement of
environment in India. Various environmental legislations/rules applicable to the proposed
project facilities are as follows.
Table 8.1.1 Indian Environmental Legislation
Legal Instrument
Relevant articles/provisions
The Environment (Protection) Section 7: Not to allow emission or discharge of
Act, 1986, amended up to environmental pollutants in excess of prescribed standards
1991
Section 8: Handling of Hazardous substances
Section 10: Power of entry and inspection
Section 11: Power to take samples
Section 15 – 19: Penalties and procedures
The Air (Prevention and Section 21: Consent from State Boards
Control of Pollution) Act Section 37: Penalties and Procedures
1981, as amended upto
1987.
The Water (Prevention and Section 24: Prohibition on disposal
Control of Pollution) Act, Section 25: Restriction on New Outlet and New Discharge
1974, as amended upto Section 26: Provision regarding existing discharge of
1988.
sewage or trade effluent
Environment
(Protection)
Rules, 1986 (Amendments in
1999, 2001, 2002, 2002,
2003, 2004, March 2008 )
Template No. 5-0000-0001-T2 Rev. 1
Rule 3: Standards for emissions or discharge of
environmental pollutants
Rule 5: Prohibition and restriction on the location of
industries and the carrying on process and operations in
different areas
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 3 of 22
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Legal Instrument
Hazardous
Wastes
(Management and Handling)
Rules, 2008, amended up to
2009
Manufacture storage and
import
of
hazardous
chemicals
rules
1989
amended 2000
EIA Notification 2006 and
subsequent amendments
Noise Pollution (Regulation
and Control) Rules, 2000,
amended up to 2010.
MoEF
notification
dated
March 18, 2008 vide circular
no G.S.R 186(E) for Oil
Refinery Industry
MoEF
notification
dated
November 9, 2012 vide
circular no G.S.R 820(E) for
Petrochemical (Basic and
Intermediaries) Industry
Relevant articles/provisions
Rule 13: Prohibition and restriction on the handling of
hazardous substances in different areas
Rule 14: Submission of environmental statement
Rule 4:Responsibility of the occupier and operator of a
facility for handling of wastes
Rule 8: Disposal sites
Rule 20: Responsibility of waste generator
Rule 4: Responsibility of operator
Requirements and procedure for seeking environmental
clearance of projects
Ambient noise standards and requirements of DG sets
Revised standards for
environmental pollutants
emissions
or
discharge
of
Revised standards for
environmental pollutants
emissions
or
discharge
of
The proposed project shall be designed taking into account the above-referred legislations/rules
and as per the directives of Environmental Clearance documents. Besides this, the proposed
effluent and emission standards for Petroleum Refineries will also be compiled for this Project.
A brief description of the environmental protection measures proposed to be adopted in the
project both in the operation and construction phase with respect to the various components of
the environment like air, water, noise, land, etc., are given in the subsequent sections.
8.2
Pollution Control Measures
In order to minimize the impact of the project on the environment, due attention is being given
for implementing effective pollution control measures. The design stage endeavors to mitigate
the problems related to health, safety and environment at the process technology/source level
itself. The design basis for all process units lays special emphasis on measures to minimize the
effluent generation at source.
During the operation of the plant, the major areas of concern will be stack emissions and
fugitive emissions of hydrocarbons from the process units and storage tanks along with
disposal of treated effluent. Handling, treatment and disposal of hazardous wastes will also be
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 4 of 22
an area of concern.
The specific control measures related to gaseous emissions, liquid effluent
treatment/discharges, noise generation, solid waste disposal, etc., along with relevant
stipulated standards are described below:
8.2.1
Air Environment
The gaseous emissions from the proposed project will be controlled to meet all the relevant
standards stipulated by the regulatory authorities. Standards applicable to this project are
classified into three categories:

Ambient Air Standards

Emission Standards

VOC control, Emission and Monitoring
8.2.1.1 Emission Standards
The emission from the new facilities envisaged in this configuration study will be conforming to
the standards stipulated by Ministry of Environment and Forests (MoE& F) vide their notification
GSR 186€ dated 18th March 2008.
Table 8.2.1.1.1 Standards for Emissions from Furnaces and Boilers*
Limiting concentration in mg/Nm3,
unless stated
Sl.
Parameter
No.
Existing
New refineries/ furnaces/
refineries
boilers
Sulphur
Gas firing
50
50
1
Dioxide
Liquid firing
1700
850
(SO2)
Oxides of
Gas firing
350
250
2
Nitrogen
Liquid firing
450
350
(NOx)
Gas firing
10
5
Particulate
3
Matter (PM)
Liquid firing
100
50
Carbon
Gas firing
150
100
4
Monoxide
Liquid firing
200
150
(CO)
Nickel +
Liquid firing
5
5
5
Vanadium
(Ni+V)
Hydrogen
Sulphide
6
Liquid / gas firing
150
150
(H2S) in fuel
gas
7
Sulphur
Liquid / gas firing
1.0
0.5
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 5 of 22
content in
liquid
fuel, weight %
*As per MoEF notification dated March 18, 2008 vide circular no G.S.R 186(E) for Oil Refinery
Industry.
The refinery complex is designed to meet all statutory requirements .Some of the major
features of these environmental measures are as follows:
(1) In case of mixed fuel (gas and liquid) use, the limit shall be computed based on heat supplied
by gas and liquid fuels.
(2) All the furnaces/ boilers with heat input of 10 MMKcal/hr. or more shall have continuous
systems for monitoring of SO2 and NOx. Manual monitoring for all the emission parameters in
such furnaces/ boilers shall be carried out once in two months.
(3) All the emission parameters in furnaces/ boilers having heat input less than 10 MM KCal/hr. will
be monitored once in a quarter.
(4)
In case of continuous monitoring, one hourly average concentration values shall be met 98% of
the time in a month. Any concentration value obtained through manual monitoring, if exceeds
the limiting concentration value, shall be considered as noncompliance.
(5) Data on Ni + V content in the liquid fuel (in ppm) shall be reported. Ni + V content in the liquid
fuel shall be monitored once in six months, if liquid fuel source & quality are not changed. In
case of changes, measurement is necessary after a change.
In addition to the above, the particulate matter in emissions from stacks should not exceed the
maximum permissible limit of 5 mg/Nm3.
The refinery complex is designed to meet all the statutory requirements. Some of the major
features of these environmental measures are as follows:

Low sulphur fuels will be used for internal fuel purpose.

Heaters/furnaces will be provided with well proven Low NOx burners to reduce the
emissions of Nitrogen Oxides (NOx).

Under normal circumstances, there will be no continuous/intermittent point releases of
volatile hydrocarbon streams. However, if during startup/shut down or an emergency
situation any hydrocarbon streams are released, they will be directed to an elevated
flare for complete combustion. This will eliminate the possibility of forming an explosive
mixture due to sudden release of unburned hydrocarbons to the atmosphere.

The flares elevation will be such that there will be no impact of thermal radiation on the
operating personnel in the refinery. To ensure complete combustion of released
hydrocarbons through flares, a pilot burner shall always be burning with the aid of fuel
gas. Further, to ensure smokeless and non-luminous flaring, the steam provision at the
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 6 of 22
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
flare tip is also envisaged.
 The heights of various stacks will be determined taking into consideration the
"Guidelines for Minimum Stack Height" as per notification by MoEF dated 19th May
1993, which fixes the minimum stack height based on emission of Sulphur Dioxide.
This is as given below:
H=14(Q) 0.3
Where
H =
Stack Height in m,
Q =
Sulphur Dioxide emission in kg/hr.
If, the Pollution Control Board specifies any minimum stack height, the higher of
be selected.
the two will
 The refinery complex is designed in such a way that the total emissions from the refinery
complex will meet all the applicable standards/stipulations.
The total Sulphur Dioxide emissions from the refinery complex after development of proposed
additional units and capacity expansion will not exceed the limit of 59 TPD (excluding Aromatic
complex). Break -up of Sulphur –Dioxide emission, both process and emission due to fuel use,
from the refinery complex are given below.
Under this configuration, the following cases have been shortlisted:
Table 8.2.1.1.2 Shortlisted cases
Shortlisted Case-1
Shortlisted Case-2
90% CONV + VGOHDT +
INDMAX LOW CCR + PRU +
PPU
70% CONV + VGOHDT +
INDMAX LOW CCR + PRU
+ PPU
Table 8.2.1.1.3 Selected case
Selected Case
70% CONV + VGOHDT + INDMAX LOW CCR +
PPU ( 450 KTPA) + ALKYLATION UNIT
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 7 of 22
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Table 8.2.1.1.4 SOx Balance for Shortlisted cases
S.No
1
SOURCE
SOx FOR
Shortlisted Case1 (kg/hr)
SOx FOR
Shortlisted
Case-2 (kg/hr)
From Refinery
723.7
444.6
Table 8.2.1.1.5 SOx Balance for Selected case
S.No
1
SOURCE
From Refinery
SOx FOR Selected
Case (kg/hr)
1091.1
It is evident from the table above that SOx is well within the limit of 1275 kg/hr for the selected
case.
8.2.1.2
Ambient Air Standards
The ambient air quality around the premises will be limited to those limits as per National
Ambient Air Quality Standards, which are given below:
Table 8.2.1.2.1 National Ambient Air Quality Standards (Gazette No. 217 dated 18
November 2009)
Sl. No. Pollutant
Time
Concentration in Ambient Air
Weighted
Industrial,
Methods of
Ecologically
Average
Residential,
measurement
Sensitive
Rural & other
Area
areas
Annual
50 µg/m3
20 µg/m3
-Improved West and
Sulphur
Average*
Gaeke
1.0
Dioxide
80 µg/m3
80 µg/m3
-Ultraviolet
(SO2)
24 hours**
Fluorescence
40 µg/m3
30 µg/m3
-Modified Jacob &
Annual
Oxides of
Hochheiser (NaAverage*
2.0
Nitrogen as
Arsenite)
NO2
24 hours**
80 µg/m3
80 µg/m3 Chemiluminiscence
Annual
60 µg/m3
60 µg/m3
-Gravimetric
Particulate
Average*
-TOEM
3.0
Matter ,
Size<10 µ
24 hours**
100 µg/m3
100 µg/m3
-Beta attenuation
Annual
40
µg/m3
40
µg/m3
-Gravimetric
Particulate
Average*
-TOEM
4.0
Matter ,
Size<2.5 µ
24 hours**
60 µg/m3
60 µg/m3
-Beta attenuation
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 8 of 22
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Sl. No.
Pollutant
Time
Weighted
Average
8 hours**
5.0
Ozone O3
1 hour
6.0
Lead(Pb)
0.5 µg/m3
0.5 µg/m3
1.0 µg/m3
1.00 µg/m3
2 mg/m3
2 mg/m3
4 mg/m3
100 µg/m3
4.0 mg/m3
100 µg/m3
400 µg/m3
400 µg/m3
05 µg/m3
05 µg/m3
Annual
Average*
01 ng/m3
01 ng/m3
Annual
Average*
06 ng/m3
06 ng/m3
Annual
Average*
20 ng/m3
20 ng/m3
Annual
Average*
24 hours**
7.0
8.0
Carbon
Monoxide
(CO)
Ammonia
(NH3)
9.0
Benzene
10.0
Benzo(a)Py
rene (BaP)
11.0
12.0
Arsenic (As)
Nickel (Ni)
Concentration in Ambient Air
Industrial,
Methods of
Ecologically
Residential,
measurement
Sensitive
Rural & other
Area
areas
100 µg/m3
100 µg/m3
-UV Photometric
Chemilminescence
180 µg/m3
180 µg/m3
Chemical method
8 hours**
1 hour
Annual
Average*
24 hours**
Annual
Average*
AAS/ICP method after
sampling on EPM
2000 or equivalent
filter paper
-ED-XRF using Teflon
filter
Non Dispersive
Infra red(NDIR)
Spectroscopy
Chemiluminescence
Indophenol blue
method
Gas chromotography
based continues
analyzer
Adsorption and
Desorption followed
by GC analysis
Solvent extraction
followed by HPLC/GC
analysis
AAS/ICP method after
sampling on EPM
2000 or equivalent
filter paper
AAS/ICP method after
sampling on EPM
2000 or equivalent
filter paper
* Annual Arithmetic mean of minimum 104 measurements in a year taken twice a week 24 hrs. at
uniform interval.
** 4 hourly/8 hourly values should be met 98% of the time in a year. However, 2% of the time, it
may exceed but not on two consecutive days.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 9 of 22
Whenever and wherever monitoring results on two consecutive days of monitoring exceed the
limits specified above for the respective category, it shall be considered adequate reason to
initiate regular or continuous monitoring and further investigation.
8.2.1.3
VOC Control, Emission and Monitoring
Fugitive emissions are primarily due to intermittent/continuous leakage or evaporation of
Volatile Organic carbons (VOCs) from processing/storage area of the refinery.
The major sources of such fugitive emissions of VOCs in the refinery are the main processing
area, the storage tank farm area for crude oil & products and the loading/unloading gantry area.
These fugitive emissions originate from the static and dynamic compressor joints and seals
used in flanges, pumps, valve packings and connection joints to the atmosphere like sampling,
relief valves, etc. In order to minimize the fugitive emissions, the following measures will be
taken during engineering:

Minimum number of flanges, valves, etc.

High grade gasket material for packing.

Usage of state-of-the-art low leakage valves preferably with bellow seals.

Usage of pumps with Double Mechanical seals for light hydrocarbon services.


Provisions of floating roof storage tanks.
Provisions of double seal in some of storage tanks.

Provision of covering the oil-water separation units in ETP.

Provision of seals in the drains and manholes.
Storage of General Petroleum Products:
Requirements on type of storage tanks shall be as follows:
Sl.
No.
1
2
3
4
Table 8.2.1.3.1 Types of Storage Tanks
Total Vapor
Tank
Pressure
Type of Storage Tank
Capacity, m3
KPa
> 10
4 – 75
Fixed Roof Tank (FRT) with pressure valve vent
Internal Floating Roof Tank (IFRT) or External
10 – 76
75 – 500
Floating Roof Tank (EFRT) or Fixed Roof Tank
with vapour control or vapour balancing system
Internal Floating Roof Tank or External Floating
10 – 76
> 500
Roof Tank or Fixed Roof Tank with vapour
control system
> 76
> 75
Fixed Roof Tank with vapour control system
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 10 of 22
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Notes:
1. Requirement for seals in Floating Roof Tanks:
I. IFRT & EFRT are to be provided with double seals with minimum vapor recovery of 96%.
II.
Primary seal shall be liquid or shoe mounted for EFRT and vapour mounted for IFRT.
Maximum seal gap width will be 4 cm and maximum gap area will be 200 cm 2/m of tank
diameter.
III.
Secondary seal will be rim mounted. Maximum seal gap width will be 1.3 cm and maximum
gap area will be 20 cm2/m of tank diameter.
IV.
Material of seal and construction should ensure high performance and durability.
2. Fixed Roof Tanks will have vapor control efficiency of 95% and vapor balancing efficiency of
90%.
3. Inspection and maintenance of storage tanks should be carried out under strict control. For the
inspection, API RP 575 may be adopted. In-service inspection with regard seal gap should be
carried out once in every six months and repair to be implemented in short time. In future,
possibility of on-stream repair of both seals will be examined.
VOC Emission Standard:
(I)
Standards for emissions from storage of volatile liquids are as follows
Table 8.2.1.3.2 Standards for emissions from storage of volatile liquids
Sl.
Item
Standards
No.
Gasoline, Naphtha, Benzene, Toluene,
1
Applicable products
Xylene
Type of loading: (i) Road tank truck
2
(i) Bottom loading (ii) Top submerged
(ii) Rail tank wagon
3
Leak testing for Vapour collection
Annual leak testing
Emission control for Road tank truck/ Rail tank wagon loading
Gasoline and Naphtha: (i) VOC
4
(i) 99.5 or (ii) 5
reduction, % or (ii) Emission, gm/m3
Benzene: (i) VOC reduction, % or (ii)
6
(i) 99.99 or (ii) 20
Emission, mg/m3
Toluene/Xylene: (i) VOC reduction, %
7
(i) 99.98 or (ii) 150
or (ii) Emission, mg/m3
(II) Standards for VOC emissions from wastewater collection and treatment:
a) All contaminated and odorous wastewater streams should be handled in closed systems from
the source to the primary treatment stages (oil-water separator and equalization tanks).
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 11 of 22
b) The collection system should be covered with water seals (traps) on sewers and drains and gas
tight covers on junction boxes.
c) Oil-water separators and equalization tanks should be provided with floating/ fixed covers. The
off-gas generated should be treated to remove at least 90% of VOC and eliminate odor. The
system design should ensure safety (prevention of formation of explosive mixture, possible
detonation and reduce the impact) by dilution with air/ inert gas, installing LEL detector
including control devices, seal drums, detonation arrestors, etc. The system should be
designed and operated for safe maintenance of the collection and primary treatment systems.
d) Wastewater from aromatics plants (benzene and xylene plants) should be treated to remove
benzene/ aromatics to a level of 10/20 ppm before discharge to effluent treatment system
without dilution.
VOC Monitoring:
The standards call for stringent monitoring programme in form of LDAR which is described
below:
a) Approach: The approach for controlling fugitive emissions from equipment leaks is to have
proper selection, installation and maintenance of non-leaking or leak tight equipment. Following
initial testing after commissioning, the monitoring for leak detection is to be carried out as a
permanent on-going Leak Detection and Repair (LDAR) programme. Finally detected leaks are
to be repaired within an allowable time frame.
b) Components to be covered: The components that shall be covered under LDAR programme
include (i) Block valves; (ii) Control valves; (iii) Pump seals; (iv) Compressor seals; (v) Pressure
relief valves; (vi) Flanges – Heat Exchangers; (vii) Flanges – Piping; (viii) Connectors – Piping;
(ix) Open ended lines; and (x) Sampling connections. Equipment and line sizes more than
1.875 cm or ¾ in. are to be covered.
c) Applicability: The LDAR programme would be applicable to components (given at 2 above) for
following products/ compounds: (i) hydrocarbon gases; (ii) Light liquid with vapour pressure @
200C > 1.0 kPa; and (iii) Heavy liquid with vapour pressure @ 200C between 0.3 to 1.0 KPa.
d) While LDAR will not be applicable for heavy liquids with vapour pressure < 0.3 kPa, it will be
desirable to check for liquid dripping as indication of leak.
e) Leak definition: A leak is defined as the detection of VOC concentration more than the values
(in ppm) specified below at the emission source using a hydrocarbon analyzer according to
measurement protocol (US EPA – 453/R-95-017, 1995 Protocol for equipment leak emission
estimates may be referred):
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 12 of 22
Table 8.2.3.1.3 Estimates of equipment leak emissions
General Hydrocarbon
Benzene
(ppm)
(ppm)
Sl. No
Component
w.e.f
w.e.f
Till 31st
Till 31st
January
January
Dec.2008
Dec.2008
01,2009
01,2009
Pump/
1
10000
5000
3000
2000
Compressor
2
Valves/ Flanges
10000
3000
2000
1000
Other
3
10000
3000
2000
1000
components
f)
In addition any component observed to be leaking by sight, sound or smell, regardless of
concentration (liquid dripping, visible vapor leak) or presence of bubbles using soap solution
should be considered as leak.
g) Monitoring requirements and repair schedule: Following frequency of monitoring of leaks and
schedule for repair of leaks shall be followed:
Table 8.2.3.1.4 Monitoring Schedule of VOC emission
Sl.
No.
1
2
3
4
5
6
7
8
9
10
Component
Frequency of monitoring
Repair schedule
Valves/ Flanges
Quarterly (semiannual after
two consecutive periods
with < 2% leaks and annual
after 5 periods with < 2%
Repair will be started
leaks)
within 5 working days
and
shall
be
Pump seals
Quarterly
completed within 15
Compressor seals
Quarterly
working days after
Pressure
relief
Quarterly
detection of leak for
devices
general hydrocarbons.
Pressure
relief
In case of benzene,
devices
(after Within 24 hours
the leak shall be
venting)
attended immediately
Heat Exchangers
Quarterly
for repair.
Process drains
Annually
Components
that Annually
are
difficult
to
monitor
Pump seals with Immediately
Immediately
visible liquid dripping
Any component with Immediately
Immediately
visible leaks
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Sl.
No.
11
Component
Frequency of monitoring
Any component after Within five days
repair/ replacement
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 13 of 22
Repair schedule
-
h) The percentage leaking components should not be more than 2% for any group of components
monitored excluding pumps/ compressors. In case of pumps/ compressors, it should be less
than 10% of the total number of pumps/ compressors or three pumps and compressors,
whichever is greater.
i)
Emission inventory: The refinery shall prepare an inventory of equipment components in the
plant. After the instrumental measurement of leaks, emission from the components will be
calculated using stratified emission factors (USEPA) or any other superior factors. The total
fugitive emission will be established.
j)
Monitoring: Following types of monitoring methods may be judiciously employed for detection of
leaks: (i) Instrumental method of measurement of leaks; (ii) Audio, visual and olfactory (AVO)
leak detection; and (iii) Soap bubble method.
k) Data on time of measurement & concentration value for leak detection; time of repair of leak;
and time of measurement & concentration value after repair of leak should be documented for
all the components.
l)
The pressure relief and blow down systems should discharge to a vapor collection and recovery
system or to flare.
m) Open-ended lines should be closed by a blind flange or plugged.
n) Totally closed-loop should be used in all routine samples.
o) Low emission packing should be used for valves.
p) High integrity sealing materials should be used for flanges.
8.2.1.4
Odor Control
Odor from the refinery complex originates due to fugitive emissions of hydrocarbons, the
burning of Sulphur containing fuels, the presence of Sulphides and VOCs in the effluent, the
addition of mercaptans to LPG to detect its leakage, etc. Therefore, the design measures
suggested as part of controlling stack and fugitive emissions are applicable for odor control as
well.
8.2.2
Noise Environment
Ambient Standard for Noise, specified by CPCB is given below:
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 14 of 22
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
S. No.
1.0
2.0
3.0
4.0
Table 8.2.2.1 Noise (Ambient Standards)
Area Code
Category of Area
Limit in dB (a) Leg
Day Time
Night Time
A
Industrial area
75
70
B
Commercial area
65
55
C
Residential area
55
45
D
Silence zone
50
40
Notes:
(1) Daytime is reckoned in between 6 a.m. and 9 p.m.
(2)
Nighttime is reckoned in between 9 p.m. and 6 a.m.
(3)
Silence zone is defined as areas up to 100 meters around such premises hospitals,
educational institutions and courts. The silence zones are to be declared by the
competent authority.
(4)

Mixed categories of areas should be as "one of the four abovementioned categories"
by the competent authority and the corresponding standard shall apply.
Comprehensive measures for noise control will be followed at the design stage in terms of:
Noise level specification of various rotating equipment as per Occupational Safety and Health
Association (OSHA) standards.

Equipment layout considering segregation of high noise generating sources.

Erecting suitable enclosures, if required, to minimize the impact of high noise generating
sources.

Sizing the flare lines with low Mach number to have lower noise levels.

Green belt of appropriate width all around the refinery towards noise attenuation.
8.2.3
Water environment
The maximum water requirement for various purposes in the shortlisted cases is given below:Table 8.2.3.1: Raw Water Balance
Circulating Cooling Water
makeup
DM water
Drinking Water
Service Water
Template No. 5-0000-0001-T2 Rev. 1
Raw Water Balance
90% CONV +
VGOHDT +
INDMAX LOW
CCR + PRU + PPU
M3/hr
1515
M3/hr
M3/hr
M3/hr
30
50
70% CONV +
VGOHDT +
INDMAX LOW
CCR + PRU + PPU
1530
30
50
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Fire Water makeup
M3/hr
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 15 of 22
250
250
The maximum water requirement for various purposes in the selected case is given below:
Raw Water Balance
Circulating Cooling Water
makeup
DM water
Drinking Water
Service Water
Fire Water makeup
M3/hr
70% CONV + VGOHDT +
INDMAX LOW CCR + PRU +
PPU
1350
M3/hr
M3/hr
M3/hr
M3/hr
30
50
250
A comprehensive wastewater management system shall be made available in the refinery to
treat the liquid effluent to meet the Minimal National Standards (MINAS) and State Pollution
Board requirements for refinery.
The waste water management system in the refinery consists of the following:
Process wastewater treatment

Floor wash and contaminated Rain water treatment

Spent caustic Treatment

Tertiary Treatment Plant

Sanitary Effluent Treatment Plant
8.2.3.1
Liquid Summary
The typical liquid effluents from different new facilities envisaged in this study are
below:
Unit
CDU/ VDU
Template No. 5-0000-0001-T2 Rev. 1
Table 8.2.3.1.1 Liquid Effluents
Continuous/
Effluent Stream
Intermittent
Continuous
Brine from
desalter
summarized
Estimated Quality
PH : 7.5-8.0
BOD @ 20oC: 300 mg/lit
COD : 500 mg/lit
Suspended Solids : 150 mg/lit
Total dissolved solids : 2500
mg/lit
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Intermittent
Spent Caustic
Intermittent
2-3 days Once in 2- Decoking effluent
3 years
Intermittent
30 mins Once in 8
hrs
70% conversion
Intermittent
90% conversion
Intermittent
VGO HDT
Intermittent/
Caustic degasser
Continuous /
Steam generator
Intt/ Cold high
press sep
Steam generator
Neutralizing
solution
Neutralizing
solution
Spent caustic
Waste water
Spent caustic
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 16 of 22
Total oil content : 200 mg/lit
Free/ Fixed Ammonia : 50 mg/lit
Cyanides : 3 mg/lit
Phenolic compounds : 3 mg/lit
H2S : 50 mg/lit
Sulfides as S : 5 mg/lit
Sodium 1875 mg/lit
Calcium 250 mg/l
Magnesium 375 mg/l
PH:11-12
BOD @, 20°C:35000 mg/lit
COD: 40000 mg/lit
Suspended Solids: 200 mg/lit
Total Dissolved solid:200000
mg/lit
Sulphur: 8000 mg/lit
Phenolic Compounds:800 mg/lit
Suspended solids: 50 mg/l
Total oil content 100 mg/l
pH 9.0-10.0
TDS 1000-6000 mg/l
Total oil content 1.0 mg/l
Phosphates 50 mg/l
Si-Sio2 50 mg/l
Alkalinity 300-400 mg/l
KmnO4 value <500 mg/l
Water : 98wt% , Soda Ash 2 wt%
Hydrocarbon < 0.1
Water : 98wt% , Soda Ash 2 wt%
Hydrocarbon < 0.1
S.G=.99,Visc=0.6cp,NaHS=
50 ppmv Na2S=13ppmv
S.G=1.0,Visc=0.7cp
S.G.1.05, Visc=1.7 cp,pH=7.5-8.5
TDS<10% NaHCO3=4.7
Wt% Na2SO3=5.3-10wt%
Intermittent
(6 hr flow in 24 hr
cycle)
Sour Water
Water: 100 wt.%, H2S<1ppm.
INDMAX
Intermittent
(Once per day for
45 min)
Template No. 5-0000-0001-T2 Rev. 1
Spent Caustic
Wt.% NaOH= ~3.9 wt.%
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Intermittent
Sour Water
Sour Water Contaminants
(wppm): H2S= 150,NH3 =346,
Phenols =538, Cyanide= 1,
Hydrocarbon=150,
Mercaptans=101
Intermittent
Steam generator
Blowdown
Water: 100 wt.%
Spent Caustic
DHDT
Kero HDS
MS Block
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 17 of 22
Continuous
Rich Amine
Continuous
Sour Water
Intermittent
Water from
Debutanizer
Receiver Boot
Intermittent
(once a week for
3hr)
Continuous
Spent Caustic
from Spent
Caustic
Degassing Drum
Sour Water from
Flash
Drum
NH4)2SO4=0.3% wt=
NA2CO3=7.5% wt
Na2SO3=5.7% wt
MDEA – 39.6 Wt%
H2S – 1.7 Wt%
H2S – 1.5 wt%
NH3 – 0.5 wt%
NaCl: 10-12 wt.%, NaOH: 2 wt.%,
Hydrocarbon: Saturated
NH3: 132 ppm, H2S: 295 ppm.
Continuous
Boiler blow down
pH 9.0-10.0
TDS 1000-6000 mg/l
Total oil content 1.0 mg/l
Phosphates 50 mg/l
Si-Sio2 50 mg/l
Alkalinity 300-400 mg/l
KmnO4 value <500 mg/l
Intermittent
4 seconds once a
shift
Boiler Blow down
Same as above
Stripped Water
(1)
H2S : 50 PPMW
Ammonia : 50 ppmw
Boiler blow down
pH 9.0-10.0
TDS 1000-6000 mg/l
Total oil content 1.0 mg/l
Phosphates 50 mg/l
Si-Sio2 50 mg/l
Alkalinity 300-400 mg/l
Hydrogen Unit
SWS
SRU
Template No. 5-0000-0001-T2 Rev. 1
Continuous
Continuous
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 18 of 22
KmnO4 value <500 mg/l
Continuous
Waste Water
Cooling Water
Continuous
Blow
Down
Flare
Continuous
Water seal drum
Sanitary Waste
Continuous
Water
ARU
5 m3/hr Oil:200ppm
Utilities
1.
2.
3.
4.
5.
PH ; 7.5 – 8.5
Suspended solids, mg/lit : 50
NTU
Dissolved solids, mg/lit : 5000
pH : 7.0 – 8.0
Oil: 50-100mg/l
HC: 100 mg/l
Notes:During normal operation, sour water will be generated from Hydro processing units for which
SWS of approximate capacity 165 m3/hr and 220 m3/hr for shortlisted case-1 and shortlisted
case-2 respectively is provided. A part of stripped sour water will be reused while a portion will
be sent to ETP for treatment.
Most of the stripped water from hydro processing Sour Water Stripper will be reused in hydro
processing units. This in-plant control measure will reduce the net wastewater load to the ETP
considerably.
Closed blow down system will be incorporated for hydrocarbon liquid discharges in all the
process units, which will reduce the wastewater load to ETP both in terms of quantum load and
quality. This is another of the in-plant control measures.
Appropriate segregation and collection philosophy (separate sewers for process waste,
contaminated rainwater, spent caustic, cooling tower blow down, boiler blow down, catalyst
regeneration waste, etc. will be incorporated for various effluents depending on individual
stream characteristics.
Process area will be paved to avoid contamination of soil/sub-soil/ground water in case of
accidental spill/leakage of hydrocarbon liquids.
The various process streams shall be brought to ETP battery limit separately
Table 8.2.3.2 Liquid Effluents
STREAM TYPE
S.No
1
Oily Stream From Process Units
2
Boiler & Cooling Water Blow Down
3
Contaminated Rain Water
4
Sanitary Waste
5
Spent caustic
Oily Effluent Streams
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 19 of 22
Continuous liquid effluent if any from the various new facilities envisaged in this study will be
collected & routed to existing effluent treatment plant.
Boiler & Cooling Tower Blow Down
Boiler blow down shall be collected at the ETP Battery Limit and shall be considered under
combined flow to be adopted for Reuse and recycle option
Sanitary Effluents
Sanitary waste from the new units envisaged in this study shall be routed to new effluent
treatment unit.
8.2.4 LAND ENVIRONMENT
During the design stage itself due care will be taken to select the process technologies
generating minimum solid wastes so that their handling, treatment and disposal do not cause
any serious impact on the existing land environment. Also, efforts will be made to recycle some
of the spent catalysts by way of returning to the original supplier for reprocessing.
The solid wastes management plan proposed is briefly described below. The provisions of
Hazardous Waste (Management & Handling) Rules, 2008, amended up to 2009, will be
complied with.
There are primarily four types of solid wastes generated in a refinery:
1.
2.
3.
4.
Spent Catalyst /Chemicals
ETP Sludge’s
General Solid Wastes
Tank Bottoms Sludge
Spent Catalyst/Chemicals
Patented catalysts are used in various refinery process units. Some of the spent catalyst will be
sent back to the original supplier for reprocessing. The other catalysts are normally sent to a
secured landfill. The chemicals used in various process units will be procured, stored inside the
closed vessel inside the refinery and used as per the rules of “Manufacture Storage and import
of hazardous chemicals Rules 1989, amended 2000”.
ETP Sludge
The oily & chemical sludge separated in different units of ETP shall be dewatered, handled and
disposed so as to produce zero effluent discharge. The bio sludge from bio-treatment section
will be separately dewatered and utilized inside the refinery as manure.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 20 of 22
General Solid Wastes
Small quantities of non-hazardous, non-recyclable solid waste consisting of waste refractory,
spent insulation, decoking solid waste used filter cartridges, spent charcoal, spent clay and
sand will be generated will be sent to nearby authorized landfill agency for further disposal.
Tank Bottom Sludge
This sludge is generated periodically during the tank cleaning operations approx 1000 T/ tank at
the periodicity of 5 years. Tank bottom sludge shall be handled and disposed as per existing
practice.
8.2.5 Construction Phase
The overall impact of the pollution on the environment during construction phase is localised in
nature, reversible and is for a short period.
Air
The suspended particulate pollution generated during transportation will be mitigated by
covering the vehicles so as to ensure no spillage. Hosing down the wheels of the vehicles with
water and providing washing troughs for them would further mitigate the amount of dust
generated. In addition, emission of other pollutants from construction machinery using diesel
driven prime movers, will be controlled by proper maintenance.
Noise
Noise emissions from construction equipment will be kept to a minimum by regular
maintenance. Heavy and noisy construction work will be avoided during night time.
Water
The existing drinking and sanitation facilities at the refinery will be extended to the construction
workforce. This is necessary to reduce pollution of any receiving water body and also to prevent
hazards due to water borne vectors. Potable water shall be provided to the workers.
Socio Economic
Being the proposed project, small in terms of construction, there will be no permanent impact
on the existing socio-economic system around the refinery.
8.2.6 Operation and Maintenance Phase
It is envisaged that with strict adherence to the pollution prevention and control measures
during the design stage, the environmental impacts could be moderated to the minimum
possible level during the operation phase.
Air
A)
In-plant Control Measures
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 21 of 22
Some of the important operational measures, which can reduce the impact on air environment,
are as follows:

Ensuring the operations of various process units as per specified operating guidelines/operating
manuals.

Strict adherence to maintenance schedule for various machinery/equipment.

Good housekeeping practices
B) Stack and Ambient Air Monitoring
In order to keep a check on the emissions of SO2, NOx, SPM and CO from reactor/regenerator,
boiler and furnace stacks shall be monitored as per statutory regulations. Continuous monitors
for emissions shall be installed on all major stacks. Ambient Air Monitoring Stations shall
continuously monitor quality of the air in the vicinity of the refinery premises. Sophisticated
instruments for measuring Sulfur Dioxide, NOx, Hydrocarbon, and Carbon Monoxide shall be
used in these Monitoring Stations.
Noise
As the plant is going to be operational on a 24-hour basis, noise considerations are very
important. All equipments will be specified to meet 85 dB (A) at 1 m distance. The exposure of
employees working in the noisy area shall be monitored regularly to ensure compliance with the
OSHA requirements.
A green belt of appropriate width exists around the refinery. Treated effluent from the
wastewater treatment plant will be used for irrigating this belt. This green belt will help to
reduce the noise and visual impact upon the surrounding population as much as possible.
Water
A) In-plant Control Measures
Some of the measures, which can be taken up during operational phase of the complex are:

Reducing the actual process water consumption by way of improvement in operation of
processing units.

Looking into more options of reusing the treated effluent besides fire water make up or for
horticulture development.

Ensuring proper monitoring and maintenance schedule for the effluent treatment plant.

Providing reuse and recycle of the treated effluent and water.
B) Water Quality Monitoring
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Environmental Considerations
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 8,Page 22 of 22
The monitoring of raw influent, the intermediate stages of Effluent Treatment Plant, the treated
effluent, the receiving water body and the ground water quality in the surrounding areas will be
carried out regularly. For regular monitoring of the operation of various pollution control
facilities, a laboratory with sophisticated instruments and well-trained manpower shall be
established. A separate Pollution Control Cell with qualified Chemical Engineers/Scientists also
form part of the facility, which will ensure that all pollution control measures are effectively
operating and to carry out day-to-day checks, trouble shooting and further improvements
wherever necessary
Land
To improve the environmental quality following measures are recommended.

The solid waste generated in the form of packaging material etc. shall be sold off for making it
suitable for reuse by reprocessing.

The solids wastes identified to be disposed off in the landfill shall be done as per scientifically
established procedure for land filling.

In order to improve the aesthetics in the plant surrounding, further plantation shall be carried
out the around the plant boundary.
Socio-Economic
Being the proposed project, small in terms investment, there will be no permanent impact on
the existing socio-economic system around the refinery. However, IOCL shall take part actively
in the overall development of the area.
8.2.7 Environment Cell
A Plant Safety & Environment Department under its technical services department, which
consists of well-qualified and experienced technical personnel from the relevant fields will be in
place to look after Environment cell.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Implementation & Schedule
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 9,Page 1 of 6
CHAPTER 9
PROJECT IMPLEMENTATION AND SCHEDULE
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Implementation & Schedule
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
9.0
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 9,Page 2 of 6
INTRODUCTION
The main purpose of implementation schedule for realization of the expansion from 15.0
MMTPA to 25.0 MMTPA project at IOCL Panipat is to define an approach to a sequence
of planned events to allow the progress of the work to be achieved in the set time frame
and within the planned budget.
Two options have been shortlisted in the study. The options listed are as follows:A. 90% conversion + VGOHDT + INDMAX low CCR + PRU + PPU
B. 70% conversion + VGOHDT + INDMAX low CCR + PRU + PPU
Out of these two shortlisted case, latter case is the selected configuration for this study
and hence schedule for this case is presented in this chapter.
9.1
Selected case (70% Conversion Case)
The Proposed major facilities envisaged for this case are as follows:
Table: Capacity of new units for the selected case

UNITS
UOM
UNIT CAPACITY
CDU / VDU
PRU
PPU
NHT
CCR
ISOM
DHDT
KERO HDS
VGO-HDT
INDMAX
70% CONVERSION
ALKYLATION UNIT
LPG Merox Unit
Hydrogen Generation Unit
SW stripper unit -I
SW stripper unit -II
Amine Regeneration Unit
Sulphur Recovery Unit
MMTPA
KTPA
KTPA
MMTPA
MMTPA
MMTPA
MMTPA
MMTPA
MMTPA
MMTPA
MMTPA
KTPA
KTPA
KTPA
M3/H
M3/H
TPH
TPD
10.0
990.0
450.0
0.8
0.6
0.2
0.7
2.7
2.2
2.2
2.8
670.0
108.0
65.0
240.0
230.0
930.0
2X324
Utility systems and Offsite Tankages and pumps are also envisaged for the selected
case.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Implementation & Schedule
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
9.2
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 9,Page 3 of 6
Mode of Project execution
The project shall be implemented through hybrid mode.
Instead of considering the entire project on EPCM basis, it was suggested by client to
consider some units on EPC basis. 70% bottom hydro processing unit, VGO HDT &
DHDT will be implemented on EPC mode of execution and HGU will be implemented on
LEPC mode of execution.
9.3
9.3.1
Project execution methodology
EPCM Mode of Execution:
In this mode of execution, the Owner line up a Consultant to perform the following
activities and Owner has responsibility for placement of orders and contracts.








9.3.2
Residual Process Design
Detailed Engineering
Contracts and Purchase
Inspection
Shipping
Construction Supervision
Commissioning Assistance
Overall Project Management and control
EPC mode of execution
EPC stands for Engineering, Procurement, and Construction and is a prominent
form of contracting agreement in the construction industry. The engineering and
construction contractor will carry out the detailed engineering design of the
project, procure all the equipment and materials necessary, and then construct to
deliver a functioning facility or asset to their clients. Companies that deliver EPC
Projects are commonly referred to as EPC Contractors.
In this mode of execution, EPC contractor has to execute and deliver the project
within an agreed time and budget, commonly known as a Lump Sump Turn
Key(LSTK) Contract. An EPC LSTK contract places the risk for schedule and
budget on the EPC Contractor. The client may require specialist help and bring on
board Project Management Consultants (PMC) to assist.
9.3.3 LEPC (License Engineering Procurement Construction and Commissioning)
LEPC bid contracts are executed through a contract in which the contractor has to
supply the process technology in addition to engineering, procurement, construction
and commissioning.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Implementation & Schedule
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 9,Page 4 of 6
9.4 Project implementation plan
Successful execution of any project calls for well thought out project execution
strategies and an elaborate Project Implementation Plan for carrying out a whole range
of activities such as:
-
Selection of Technology
Financing
Pre project activities
Statutory approvals
Project Execution Philosophy and plan
Project coordination procedures
Project Management, monitoring, control and feedback
Management of technology transfer
Basic engineering / front end engineering
Detailed engineering
Procurement
Monitoring and Expediting of manufacturing activities
Construction management
Inventory and warehousing control
Quality assurance and quality control
Organizing and deployment of skilled labour and skilled contractors
Training of plant personnel to take over operations on completion of construction activity
Pre-commissioning, commissioning and performance testing of all systems and putting
in operation
Maintenance management
This chapter outlines the project implementation plan for this project. All the above
activities can be phased out in such a manner that the project is executed in the most
efficient and economic path.
9.5 Philosophy of execution
Project will be executed in two phases: Phase-I and Phase –II.
PHASE-I: PRE PROJECT ACTIVITIES
1.
Finalization of design basis and kick off meeting with process licensers to be completed
with-in 15 days from award.
2.
24 weeks considered for receipt of final BEDP from Process licensors from date of award.
3.
Thermal design of equipment’s, API datasheets & Control valve / safety valve sizing
considered under part of BDEP.
4.
Pre-project activities shall be executed on EPCM basis.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 9,Page 5 of 6
Project Implementation & Schedule
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL
5.
Site free from encumbrances to be handed at the start of pre-project activities.
6.
Equipment layout considered to be finalized during BDEP stage.
PHASE-II: Execution of project till Mechanical Completion, Pre-commissioning and
commissioning
1.
Zero date of the project is considered as date of award of LOA/Environmental Clearance,
whichever is later.
2.
3.
Project execution mode is hybrid mode.
Grid power / existing facilities has been considered for power supply and start up.
4.
All statutory approvals (CEA, PESO, EIA, AAI etc.) for establishment of new facilities have
been considered in scope of Client.
5.
Clubbing of MRs Covering requirement of various units shall be maximized.
6.
Provision of air freighting for imported items shall be made depend on schedule
requirement.
7.
Procurement of structural steel, cement, Plate for tanks, cable trays, cable ducts, lighting
fixtures etc have been considered under respective contractor.
8.
The erection of heavy equipment considered in respective Package contractor /
Mechanical contractor scope.
9.
Transportation of ODC shall be studied after receipt of critical datasheets from licensor.
10. Modularization shall be explored to the extent possible considering:

Better schedule Control

Reduced Overall Cost

Improved quality and productivity

Reduced Site Safety risk

Reduced Project Execution Risk

Weather impact mitigated

Maximize Quality through off site Fabrication

Minimize Site Labor Requirements

Reduced inventory management at site
11. Work permit for working inside existing units / facilities considered to be available as &
when required.
12. Construction Area for the following shall be arranged by Client :

Structure steel storage, fabrication

Piping shop fabrication

Site fabricated equipment
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved
Project Implementation & Schedule
Feasibility study for capacity
expansion of Panipat Refinery from
15.0 MMTPA TO 25.0 MMTPA
IOCL

Document No.
A328-RP-79-41-0002
Rev. No. 0
Ch. 9,Page 6 of 6
Office Space & Storage to the working agencies.
Project schedule for the selected configuration is attached in Annexure 4.
Template No. 5-0000-0001-T2 Rev. 1
Copyright EIL – All rights reserved