OVERVIEW OF PETROCHEMICALS

&NAPHTHA CRACKER

T.K.BASAKGM(PC)

IOCL-RHQ

OVERVIEW OF PETROCHEMICALS

MONOMERS

PETROCHEMICALS

SOLVENTS

DETERGENTS

Adhesives

PRODUCT CATAGORIES

POLYMERS

Thermoplastics

Plastics

Polymer

Rubber Fibre Paints /Adhesives

Thermosetting

TYPES OF POLYMERS

POLYMERS Polymeric materials with specific properties and having different application areas are:

9Plastics: polymer characterized by rigidity & stiffness having low recoverable deformation.

9Rubber: polymer characterized by flexibility & high amount of recoverable deformation

9Fibre: polymer having high melting point with highamount of crystallinity when stretched

9Paints & adhesives: polymer with tackiness enabling good bond strength

Polymerisation Chemical reaction by which

polymers are formedPolymerisation

Addition(Polyethelenes)

Condensation(Polyesters)

Techniques(Polymerisation)

Bulk EmulsionSuspensionSolution

GRADES OF A GIVEN POLYMER

-To suit application/product requirements-To meet processing requirements

Achieved through:-By varying molecular weight-If possible through molecular weight distribution-By copolymerising-By modification through the use of additives, fillers,reinforcement etc.

Basic Polymer Properties ; PE

Melt Flow Index (MFI)

Density (Crystallinity)

Molecular weight distribution (MWD)

WHY PLASTICS ?

Properties can be altered to suit the needs

Good strength/weight ratio

Tough & durable

Non toxic

Easy processability

Chemical/Moisture Resistant

Fire retardant

Do not rust/corrode.

Resistant to microbes

Attractive colours

Good weatherability

Practically maintenance free

Reusable / Recyclable

At Much Cheaper Price !!!

Polymers Per Capita Consumption a comparison

Polymers

4.015.0

21.0

0.010.020.030.0

India China World

Country

K

g

/

P

e

r

s

o

n

Per capita consumption in India is much lower than world average Ample potential for growth

KEY POLYMERS

9 POLY ETHYLENE9 POLY PROPYLENE9 POLY ESTERS9 POLYVINYL CHLORIDE9 POLY STYRENE9 POLY CARBONATE

MARKET SHARE OF PLASTIC MATERIALS

POLYMER % MARKET SHARE

POLY-ETHYLENE 33.5%POLY-PROPYLENE 19.5%

POLYESTERS 18.0%

POLYVINYL CHLORIDE

BASIC FEED STOCKS FOR

PETRCHEMICALS

9 ETHYLENE9 PROPYLENE9 PARA-XYLENE9 BUTADIENE

BASIC BUILDING BLOCKS FOR

PETRCHEMICALS

9 OLEFIN 9 AROMATICS

9 SYNTHESIS GAS

MAJOR SOURCE OFOLEFINS

9 NAPHTHA CRACKER9 GAS CRACKER

9 FCC

MAJOR SOURCE OFAROMATICS

9 NAPHTHA CATALYTIC REFORMING9 PYROLYSIS GASOLINE FROM

CRACKER

Primary Feed Stock - NAPHTHA

ROUTE SECONDARY FEED STOCK / PRODUCT

AROMATIZATION B,T,X

CRACKING C2, C3, C4 & HIGHER Olefins

FEED STOCK FROM GAS &LPG OF FCC

C2 OLEFINSC3 OLEFINSC4 OLEFINS

FEW STATISTICS

9 WORLD VARGIN NAPHTHA PRODUCTION : MORE THAN 1 BILLION TONNES PER ANNUM

9 ABOUT 40% OF NAPHTHA PRODUCED IS UTILISED FOR PRODUCTION PETROCHEMICALS

9 PRODUCTION OF ETHYLENE = 110 MMTPA9 PRODUCTION OF PROPYLENE = 65 MMTPA9 AROMATIC RAW MATERIALS = 70 MMTPA9 IN ASIA, 61% OF ETHYLENE IS PRODUCED FROM

NAPHTHA.

WHY REFINERY PETROCHEMICAL INTEGRATION

REFINING INDUSTRY FAVOURS INTEGRATION DUE TO9 SURPLUS NAPHTHA AVAILABILITY9 GASOLINE COMPOSITION CAHANGES9 INCREASE BTX RECOVERY FROM REFINERIES9 SHIFT OF FCC TOWARDS OLEFIN PRODUCTION

WHY REFINERY PETROCHEMICAL INTEGRATION

PETROCHEMICAL INDUSTRY FAVOURS INTEGRATION DUE TO

9 TO OBTAIN SECURE, LOW COST FEED SUPPLY9 ENHANCE BY-PRODUCT STREAM VALUES9 MINIMIZE COST STRUCTURE

KEY INTERFACES BETWEEN REFINERY & OLEFIN PLANT

REFINERY TO OLEFIN PLANT9 DRY GAS9 PROPYLENE9 N-BUTANE9 NAPHTHA

KEY INTERFACES BETWEEN REFINERY & OLEFIN PLANT

OLEFIN PLANT TO REFINERY9 C4 RAFFINATE9 PYROLYSIS GASOLINE9 PYROLYSIS FUEL OIL9 HYDROGEN

NAPHTHA CRACKER

NAPHTHANAPHTHA

AROMATIC COMPLEX

AROMATIC COMPLEX

PropylenePropyleneEthyleneEthylene

NAPHTHA CRACKERNAPHTHA CRACKER

PXPX

ButadieneButadiene

CBFSCBFS

PTAPTA MEGMEG DEGDEG

REFINERY REFINERY

LPGLPG MSMS SKO/ATFSKO/ATF HSDHSD COKECOKE SULPHURSULPHUR

Ethylene Oxidn.

Ethylene Oxidn.

PolymerisationPolymerisation

HAN

PolymerisationPolymerisation

Poly PropylenePoly PropyleneHDPEHDPE LLDPELLDPE

BenzeneBenzene

LAN

PRODUCTS FROM PANIPAT REFINERY COMPLEXPRODUCTS FROM PANIPAT REFINERY COMPLEX

POLYOLEFINS

HOMO POLYMER

RANDOM COPOLYMER

IMPACT COPOLYMER LDPE LLDPE HDPE

POLY PROPYLENE POLY ETHYLENE

27

Market Scenario - India

3.83.3

3.8 3.6

4.83.9

6.1

4.2

0

1

2

3

4

5

6

7

2007 2008 2009 2010

Cap Demand

Polyolefin Demand/Supply India

M

M

T

PP 10.3 %LLDPE 8.5 %HDPE 8.0 %

AAGR Forecast for Next 5 Yrs1.5

2.0

2.5

3.0

3.5

4.0

4.5

2009 2010 2011 2012 2013

S

u

p

p

l

y

/

D

e

m

a

n

d

M

M

T

P

A

Year

POSupplyDemand

PESupply

PEDemand

PPSupply

PPDemand

PPYear Supply Demand Supply Demand2009 1.8 2.0 3 1.92010 2.5 2.0 3.6 2.22011 2.9 2.7 3.7 2.62012 3.7 3.1 3.9 3.12013 4.0 3.4 4.2 3.7

PE

Effect of current slowdown

Polyolefin Demand Scenario India

Need To Export from the start

INDIAN PE MANUFACTURES

COMPANY CAPACITY KT/YEAR

INDIAN OIL 650RIL 1050HPL 550

GAIL 310TOTAL 2560

INDIAN PP MANUFACTURES

COMPANY CAPACITY KT/YEAR

INDIAN OIL 600RIL 1735HPL 275

TOTAL 2610

Conventional Design Ethylene Plant

Pyrolysis Heater GasolineFractionator

Fuel OilStripper

QuenchTower

ProcessWaterStripper

Charge GasCompressor1st - 3rd Stages

ATU,Caustic & WaterWash Tower

Charge GasCompressor4th & 5thStages

CondensateStripper

Fresh Feed Fuel Oil

Dryer Demethanizer DeethanizerAcetyleneConverter

EthyleneFractionator Depropanizer

Methylacetylene &Propadiene Converter

PropyleneFractionator

Debutanizer

W

S

W

W W

R

R

Fuel Gas Hydrogen Methane Ethane Ethylene C3 LPG Propylene Gasoline C4 Product

Typical Operating conditions of Naphtha Cracker

Naphtha cracker constitutes:

Hot section : Heaters

Mid section: Quench Tower

Cold section : Recovery

Operating temperature of heaters : 950 Deg. C

Cold section :

Minimum temperature for methane recovery: - 180 Deg.

Pressure : Around 35 Kg./cm2

Unit Capacity ( 000 MT/yr)

Naphtha Cracker Unit 857 * ( Ethylene )650 * ( Propylene)

C4 Hydrogenation Unit 482Pyrolysis Gasoline Hydrogenation Unit 720

Benzene Extraction Unit 117Butadiene Extraction Unit 137( to be taken up)Polypropylene Unit 2x300 LLDPE/HDPE Swing Unit 350Dedicated HDPE Unit 300MEG Unit 300

Panipat Naphtha Cracker Complex Configuration

* With a provision to expand to 1000 KTA ethylene & 750 KTA propylene

H2BEU

DRY GAS

C-6 Raff. recycle

NAPHTHA

NAPHTHA

Mixed C-4`s

recycle

C-5 + C-6 recycle

PGHU

C4HU

(from Ref.-PSU)

C3 RICH Stream

( from Ref.-RFCC)

RAW PY GAS

CBFSC-6 Raff. Recycle

BZ

C-5 + C-6 Recycle

BDEU

H2

BUTADIENE

MIX C4 Recycle

Hydrogenated C4

LPG

HDPE

RAW C4 MIX

H2

MEG

Butene-1

LLDPE/HDPE

H2PP

ETHYLENE

O2

PROPYLENE

Octene-1 Butene-1

Butene-1

H2

DEG

MEG

HDPE

LLDPE/HDPE

N

A

P

H

A

T

H

A

C

R

A

C

K

E

R

NAPHTHA CRACKER UNIT BLOCK FLOW DIAGRAM

H2

F.G.

H2 Expo. To Refinery

PP

PY. GASOLIN

E

CBFSC9+

Stream

PROCESS UNITSPROCESS UNITS

UNIT CAPACITY (MMTPA) LICENSOR

NAPHTHA CRACKER UNIT0.8 (ETHYLENE) ABB GLOBAL, USA

LLDPE/HDPE SWING UNIT0.35 NOVA CHEMICALS, USA

POLYPROPYLENE UNIT 0.6 BASELL POLYOLEFINS, ITALY

HDPE UNIT 0.3 BASELL POLYOLEFINS, GERMANY

MEG UNIT 0.3SCIENTIFIC DESIGN, USA

All figures are in MT/HR.

C2H4 30.00%CH4 38.00%O2 9.00% 0.27

Ar+N2 23.00% CG purgeBallast gas

0.0997 Lean CG C2H4 722.34 Recycle water

22.50 340.84 O2 23.44 0.905

Rich CG Rich CW767.99 989.8 318.62

Lean CW 622.14 383.21954.29

CW Bleed11.70 13.65

383.21

Aldehyde Purge

MP steam 49.28

MEG product MHP steamDEG product 38.14 44.37 15.06

TEG product 2.71 Waste w ater 7.34 MHP steam 57.390.12 2.90

0.16Poly glycol

0.02 MHP steam MHP steam MHP steam0.24 2.49 28.11

Process steam

Reflux

CO2 vent

EOReactionSystem

EO Scrubbing & CO2 RemovalSystem

EO Stripping &Acid Scrubbing

EOReabsorption

Cycle gas Compr

DI Unit

Glycol FeedStripper

Glycol Reaction

Glycol

Evaporation

Glycol

Drying

MEG

RefiningDEG

RefiningTEG

Refining

wasteHeatBoiler

Reclaim Compressor

MEG Process

Applications of LDPE & LLDPE

Green House Bottle Caps

Cable Sheathing Pouch

T_BASAK.pptOVERVIEW OF PETROCHEMICALS&NAPHTHA CRACKERT.K.BASAKGM(PC)IOCL-RHQOVERVIEW OF PETROCHEMICALSPolymerisationPolymers Per Capita Consumption a comparisonKEY POLYMERSMARKET SHARE OF PLASTIC MATERIALSBASIC FEED STOCKS FORPETRCHEMICALSBASIC BUILDING BLOCKS FORPETRCHEMICALSMAJOR SOURCE OFOLEFINSMAJOR SOURCE OFAROMATICSPrimary Feed Stock - NAPHTHAFEW STATISTICSWHY REFINERY PETROCHEMICAL INTEGRATIONWHY REFINERY PETROCHEMICAL INTEGRATIONKEY INTERFACES BETWEEN REFINERY & OLEFIN PLANTKEY INTERFACES BETWEEN REFINERY & OLEFIN PLANTNAPHTHA CRACKERMarket Scenario - IndiaINDIAN PE MANUFACTURESINDIAN PP MANUFACTURESConventional Design Ethylene PlantTypical Operating conditions of Naphtha CrackerPROCESS UNITS