PROPEL
1030RG
PROPEL
1120YG
Raw Materials
For Geotech
PROPEL
1250YG
PROPEL
1350YG
By
P.SHYAM KUMAR
PADC, Panipat
Ministry of Textile-FICCI Conference,FICCI ,New Delhi
19th Nov 2010
Content
 Company Profile
 IOCL in Petrochemicals
 Polymer Plants & Technology
 Geosynthetics & Applications
 Raw Materials
 Technical Support
 Customer’s benefits & Opportunities
Company Profile
Indian Oil - An Overview
 Diversified, Transnational, Integrated energy company
 Fortune 500 Global company, ranked at 105th position in 2009
 18th largest petroleum company in the World
 Sales turnover in 2008 – 09 : 2,85,337 Cr (US $ 63 bn)
Indian Oil An Overview
3 overseas subsidiaries in
SL, Mauritius & Dubai
Refinery
Pipelines
Owns 10 out of 19 Refineries in India
Refining Capacity – 60.20 MMTPA
R&D
Country’s largest network of
nearly 10,000 KM.
Marketing
17,600 RO’s, 5000 LPG Distributors, 101 AFSs,
90 Bottling Plants, 200 Bulk storage terminals & depots
2100 Lube formulations
140 Patents
Business
Development
Bio-fuels & Gas Marketing
Prod & Marketing : LAB, PTA & Polymers
Indian Oil in
PETROCHEMICALS
Indian Oil in Petrochemicals
 Linear Alkyl Benzene at Gujarat Refinery
 Capacity – 120 TMT LAB, UOP Detal Process
 Project Cost - Rs 1200 crore
 Commissioned August 2004
 Successfully operating at over 100% capacity
 PX/PTA at Panipat
 Capacity 553 TMT PTA (Invista T 10 Technology)/ 370
TMT PX, UOP Technology

Project Cost – Rs. 5000 crore
 Commissioned June 2006
 Successfully Operating at 100% capacity
 Naptha Cracker & Downstream Polymer at Panipat
 Product : LLDPE, HDPE, PP,MEG, Benzene
 Capex : Rs. 14000 Cr.
 Commissioned April 2010
Polymer Plants & Technology
IOCL Polymer Plants & Technology
Sr. No
Plant
1
Polypropylene
2
300
Spheripol – Basell
2
Dedicated HDPE
1
300
Hostalen – Basell
3
HDPE / LLDPE Swing
1
350
Sclairtech - Nova
Polypropylene Plant
Spheripol
No. of Lines Capacity per Line (KTA)
Dedicated HDPE Plant
Technology/ Licensor
Swing Plant
Hostalen
“With 1.25 Million MT capacity, IOCL will be the second largest Polyolefin producer in India”
Sclairtech
Spheripol Technology : Process Capability
Polypropylene
•
MFR: 0.3 - > 1600 g/10min
•
Xylene Insoluble: 90 – 99 (wt)%
•
Flexural Modulus 500 – 2200 MPa
•
Izod Impact Strength up to 750 J/m
•
SIT in RACO as low as 115°C
•
MP 130 - 165 ° C
Site Photo : Spheripol Line of IOCL, Panipat
Global PP Capacity – 48 MMTA
Global PP Consumption – 46.5 MMTA
Spheripol Technology Share : 45% (100 lines)
Hostalen Technology : Process capability
Site Photo : Hostalen Line of IOCL, Panipat
Dedicated HDPE
• Product Density - 0.94 – 0.965 gm/cc
• MFR - 2.2 (I21) to 60.0 (I5) dg/min
• Conversion rate up to 99.5 % for Ethylene.
• Excellent Quality & Product consistency.
• Bimodal grades.
Global HDPE Capacity – 33 MMTA
Global Consumption – 30.3 MMTA
7 MMTA of HDPE Produced by Hostalen Technology (36 lines)
Sclairtech Technology : Process Capability
Site Photo : Sclairtech Line of IOCL, Panipat
Swing Unit (HD/LLDPE)
•
Density – 0.905-0.965gm/cc
•
MFI – 0.3 – 150 gm/10min
•
High ethylene conversion > 98%
•
Short residence time in the reactor
•
Low gel level, lot-to-lot consistency
•
Capability to produce C4, C8 & terpolymers
Global PE Capacity – 77 MMTA
Global PE Consumption – 73.1 MMTA
Sclairtech Capacity : 3.5 MMTA (11 lines)
IOCL Polymer Grade Portfolio
Polyethylene
• LLDPE – 11 Grades – 0.9 MFI to 50 MFI (Butene & Octene)
• HDPE - 22 Grades – 0.1 MFI to 18 MFI (Unimodal & Bimodal)
All PE Grades will meet the requirements of IS : 10146-1982 for food contact applications, IS:10141-1982
positive list of constituents & US FDA: CFR Title 21,177.1520
Polypropylene
• Homo Polymer – 14 Grades – 2 MFI to 35 MFI
• Random Copolymers – 5 Grades - 1.8 MFI to 45 MFI (Clarified & GP)
• Impact Copolymers – 8 Grades – 3 MFI to 50 MFI (Medium to Super high
Impact)
All PP Grades will meet the requirements of IS : 10910 for food contact applications, IS:10909 positive list
of constituents & US FDA: CFR Title 21,177.1520
Geosynthetics & Applications
Geosynthetics Family
Geosynthetics
Geogrids (Woven) , Georopes,
Geonets, Geocomposites, Geocells,
PVDs(PP) etc
Geotextiles
NonWoven
Woven
Multi
Filament
Slit Tape
Needle
Punched
Indian Scenario
 Potential - 25KTA
 Imports - 53%
 Suppliers - 12
Spun
Bond
Global Trend in Geosynthetics
10
19
USA
EU
51
AUS
China
India
5
Other Asians
14
~250KTA
Applications & Functions
Application Areas
 Roads (NHAI & NRRDA)
 Railways
 Ports & Airports
 Coastal Protection
 Ground Improvement
Functions
 Separation
 Reinforcement
 Filtration & Drainage
 Containment (barrier)
 Protection
Raw Materials for Geosynthetics
Raw Materials for Geosynthetics
PP Advantages
Polymers Used
 PP ≈ 85 %
 Lower density and MP
 PET ≈ 12 %
 Low Cost
 PE ≈ 2 %
Availability
 Nylon ≈ 1 %
Polymer yarn used
 Good balance of properties
IOCL PP -Woven Grades for Geotech
Grade and Performance Attributes
 Good processability
 Good balance of tenacity & elongation.
PROPEL 1030RG
MFI- 3 (g/10min)
 Consistency in MFI gives excellent thickness control
 Tailored additive package for lower water carryover
 Grades are designed to give tenacity > 5gpd and elongation ~20%
 Isotactic Index > 95%,with FM >1450MPa
IOCL PP – F &F Grades for Geotech
Grades and Performance Attributes
PROPEL 1120YG
 Consistent medium to high melt flow
MFI- 12 (g/10min)
 Narrow to medium molecular weight distribution
 Tailored additive package
PROPEL 1250YG
 High purity
MFI- 25 (g/10min)
 Low oligomer content
 Tenacity of 2.5 - 4 g/den
PROPEL 1350YG
 % Elongation at break of 70 - 100
MFI- 35 (g/10min)
 Exhibits higher tenacity on industrial scale
Technical Support
Product Application & Development Centre - PADC
PADC is being set up at Panipat (Haryana) near
Panipat Naphtha cracker Project (PNCP).
New Grade
development
New Application
Knowledge
development
Management
Marketing
PADC
Technical
Customer
Support to
Relation
Customers
Management
PADC
PLANT
Customers
State of Art Technology Centre with sophisticated Plastic
PADC is an interface between Plant,
Processing & Characterisation equipments
Marketing & Customers
Customer Benefits with IOCL Entry
•
Ample raw material availability with IOCL entry
•
Wider PP product portfolio due to 2 Spheripol lines.
•
Plants incorporating latest developments & most sophisticated control systems for
superior lot to lot consistency.
•
Sizable plant capacities will help in stream-lining supply & pricing fluctuations
which are frequently experienced in Indian market.
•
IT Enablement – E Commerce module – Transparency and ease of transaction
•
1st PP plant in Northern region, which is 2nd largest consumption region in India –
Northern Region has potential to be largest region
•
Business opportunity with company trusted by Indians for over 50 years.
“Let’s work together for nurturing a long term business relation”
Thank you
Back - Up
Panipat Naphtha Cracker Complex (PNCC)
Feedstock 2.3 MMTPA Naphtha
• Ethylene- 857 KTA
• Propylene – 650 KTA
• Butadiene – 130 KTA
• Benzene – 130 KTA
• MEG 325 KTA
Naphtha Cracker Unit
Technology : ABB Lummus
• 650 KTA PE and 600 KTA PP
IOCL PP : Product Attributes
Bimodal Grades
Lot-to-lot consistency
Product benchmarked in
over 100 countries
Low Ash Content
Low Odour
Compliance to FDA
Excellent Organoleptic Properties
High Isotactic Index in PPHP
Excellent Processability &
High Tenacity
High Clarity of PPRCP Grades
Low Seal Temp. Grades
High Yield
High
Selectivity
Catalyst
High Ethylene Content ICPs
Excellent Extrusion Coating grades
Broad MFR Range
Reactor Grades up to 100 MI
IOCL PP : Product Envelope
HOMO POLYMER
CO POLYMER
ICP IM
(GP/FURNITURE/BATTERY/AUTO)
RCP
GP EX
RCP
ISBM
RCP
EBM
RCP
GP IM
GP IM
RCP
TWIM
TWIM
RAFFIA
BOPP
CPP
TQPP
F&F
EBM
1
NON WOVEN
10
Technology
:Spheripol
Licensor
: Basell
100
MFI (g/10min)
Plant capacity : 2 lines of 300 KTA each
Product
ICP
TWIM
ICP
EC
: Polypropylene (Homo/RCP/ICP)
IOCL Homo Polymer
IOCL RCP
IOCL ICP
IOCL HDPE (Hostalen Plant) : Product Attributes
0.940 – 0.965 g/cc
up to 60 (I5) dg/min
Excellent Dart
Impact & Sealing
Properties in Film
Grades
High Flow, High
Gloss & Low
warpage Injection
Moulding Grades
Good balance of
ESCR, Stiffness &
impact properties in
blow moulding
grades
Excellent combination
of processability & final
product performance in
bimodal grades
Good processability
& low water carry
over in Raffia Grades
Bimodal Pipe grades
complying PE63, PE80
& PE100 Requirements
IOCL HDPE (Hostalen Plant) : Product Envelope
0.97
LARGE CONTAINERS
TAPES & MONOFILAMENT
Density (g/cc)
0.96
*
INJECTION
MOULDING*
0.95
SMALL BOTTLES
PIPES
HM FILM
0.94
0.93
0.10
0.22
Technology : Hostalen
Licensor
: Basell
Capacity
: 300 KTA
Product
: HDPE
0.28
1.00
1.20
MFI (g/10 min)
2.00
18.0
MFI I5 (g/10 min)
* MFI I (g/10 min)
2
IOCL PE (Swing Plant) : Product Envelope
100
MFI (g/10 min)
LL IM
10
HD IM
EX. COATING
ROTO MOLDING
LL FILM
RAFFIA
1
W&C
PIPE COATING
0.1
0.91
0.92
0.93
0.94
Density (g/cc)
Technology
:Sclairtech
Licensor
: Nova Chemicals
Plant capacity : 350 KTA
Product
: LLDPE/ HDPE
PIPE/ PIPE COATING/
HD FILM/ BM
0.95
0.96
IOCL GRADE
0.97
IOCL HDPE (Swing Plant) : Product Attributes
Road Map
Objective:
To demonstrate Polyolefin Geosynthetics as an essential and important material for roads and
infrastructure projects for for long lasting performance and cost benefits.
Break up of Activities
Interactions with Nodal Agencies – On going
• Civil Bodies (MOSRTH,NHAI,NRRDA,FICCI & PWD’s / R&B’s
• Testing Bodies (CRRI, IIT’s /IISC,BTRA & ITC)
• Accreditation & Approval Bodies (IRC,RDSO & BIS)
Interactions with Consultants/Manufactures – On going
• Techfab, Garware, Maccaferi &Gayatri
• BCH,Terram & Polyfelt
Interactions with Turnkey Contractors -Planned
• NHAI Approved Contractors
• NRRDA ,PWD’s & R&B’s Contractors
Promotional Tools & Ways – Under Preparation
• Presentations ,Testimonials & Case studies
• Provide inputs on Projects, Guide lines & Tenders
• CRM with above all agencies
IOCL PE (Swing Plant) : Product Envelope
Types
Denier
Functions
Tapes
1650 -1700
Reinforcement, Embankment, Separation
FDY
840x1200
Reinforcement, Embankment, Separation
Staple Fiber
3
Filtration, Separation
Typical PP Woven Geotextiles
Property
Sample 1
Sample 2
Sample 3
Mass per unit area [gsm]
250
220
180
Thickness [mm]
3.0
2.5
1.8
Apparent Opening Size [mm]
0.60
0.60
0.60
Grab tensile strength [kN]
3.0
2.5
2.0
Warp
90
70
55
Weft
85
65
50
Trapezoidal tear strength [kN]
1.5
1.2
0.75
Puncture resistance [kN]
0.90
0.75
0.60
Wide with tensile strength [kN/m]
UV resistance [ % 500 hr exposure]
50 - 70
Samples
Wide width tensile
Mass per
strength [kN/m]
unit area
[gsm]
Warp
Weft
Sample 1
90
85
250
Sample 2
70
65
Sample 3
55
50
50 -70
Thickness
[mm]
50 - 70
Thread count [per
inch]
Warp
Weft
3.0
20
18
220
2.5
15
14
180
1.8
12
11
Specifications for Polypropylene Woven Geotextiles for use in Road/
Pavement Reinforcement
Sr. No
1
2
3
4
5
6
7
8
9
10
11
12
Particulars
Material
EOS
Sp.gravity
Weight in Grms per sq.mtr
Thickness in MM
Breaking strength
(5cm x 20 cm strip)
(IS:1969-LATEST ADITION)
Warp way (kgs)
Weftway (kgs)
Elongation
(IS:1969-LATEST ADITION)
warp way
weft way
Grab strength (3"x1" strip)
(ASTM D1682)
warpway (kgs)
weftway (kgs)
Elongation % (grab test)
(ASTM D1682)
Warpway
Weftway
Tear strength (single)
(ASTM D1682)
warpway (kgs)
weftway (kgs)
Water permeability(litres/cm/sq mtr) at 10 cm.water head
width of fabric
Values
100%-polypropylene
as per site
0.91
>210
>0.59
>215
>155
<36
<33
>182
>130
<36
<33
>41
>44
>10
>2.0 mtrs
Non-Woven Geotextile standards
S.No
Property
Test Method
Values
1
Polymer
PP/PE/PET/Polyamide
2
Mass/Area
IS: 14716 /
ASTM D: 3776
250 GSM minimum
3
Thickness at 2 Kpa
ASTM: 5199
2 mm (minimum)
4
Roll width
5.0 metre (minimum)
5
Roll Length
50 m (minimum)
Mechanical Properties
1
Tensile Strength
IS: 13162 / ASTM D
4595 /
EN ISO: 10319
40kN/m (Minimum)
2
Elongation at Break
IS: 13162 /
ASTM D 4595 /
EN ISO: 10319
40 % - 70%
Hydraulic Properties
1
Apparent opening size O95
IS 14294 /
ASTM D: 4751 /
EN ISO: 12956
40 – 85 microns
2
Water Flow Rate the Plane
IS: 14324/
ASTM D: 4491
20 lit. /m2/s
(minimum)
Woven Geotextile standards
S.N
o
Property
Test Method
Values
1
2
Polymer
Mass/Area
PP/PE/PET/Polyamide
IS: 14716 /
100GSM minimum
ASTM D: 3776
3
4
Thickness at 2 Kpa
Roll width
ASTM: 5199
5.0 metre (minimum)
5
Roll Length
50 m (minimum)
1
TS at Warp
TS at Weft
Mechanical Properties
IS: 1969 /
40kN/m (Minimum)
ASTM D 4595 /
35kN/m (Minimum)
EN ISO: 10319
2
Elongation at Warp
Elongation at Warp
IS: 1969 /
ASTM D 4595 /
EN ISO: 10319
3
Puncture Strength
Puncture Strength IS:
13162 /
ASTM D: 4833
1
Apparent opening size O95
2
Water Flow Rate the Plane
0.65 mm (minimum)
15%-30 %
15%-30 %
600 N (Minimum)
Hydraulic Properties
IS 14294 /
425 microns
ASTM D: 4751 /
(maximum)
EN ISO: 12956
IS: 14324/
ASTM D: 4491
15 lit. /m2/s
(minimum)
IOCL PE (Swing Plant) : Product Envelope
Needle – Punched
Woven monofilament
Multifilament Slit Film
Calendared
(Tape x Tape)
Thermal Bonded