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VOCATIONAL TRAINING REPORT

GAIL (INDIA) LTD. U.P PETROCHEMICAL COMPLEX PATA, AURAIYA (U.P)

SUBMITTED TOTRAINING DEPARTMENT GAIL - PATA SUBMITTED BY-

Content

PAGE NO
2 3 5 6 7 8 17 23 25 26 27 31 32 41 45 46 52 58

ACKNOWLEDGEMENT INTRODUCTION OF GAIL HISTORY IOP/S

a) b) c) d)

Introduction of Boiler Utility Boiler Steam Turbine Protective Equipment

DOWN STREAM
a) b) c) d) e)

Description of HDPE Polymer formation diagram Mechanical Seal Pump LLDPE

UP STREAM
a. b. c.

Gas Sweeting Unit Gas cracker Unit LPG

ACKNOWLEDGEMENT
I would like to thank Training Department for providing me the opportunity as a vocational trainee in such a huge plant equipped with modern technology. I am deeply indebted to Mr. Santosh , Mr. Rakesh, Mr. Abhishek for his kind super vision and guidance in my training period. Here I wish my sincere gratitude towards Mr. Ajay Tripathi (DGM, Mech.), Mr. R.C. Pandey , Mr. Joyonto Panging (Ch. Manager, Mech.) for their cooperation and kind supervision throughout. Also I want to thank all the other Engineers of Service Building-2 (SB-2) , for patiently going through my innumerable questions and clearing my doubts.

INTRODUCTION
GAIL (India) Limited, is India's flagship Natural Gas company, integrating all aspects of the Natural Gas value chain (including Exploration & Production, Processing, Transmission, Distribution and Marketing) and its related services. In a rapidly changing scenario, GAIL is spearheading the move to a new era of clean fuel industrialisation, creating a quadrilateral of green energy corridors that connect major consumption centres in India with major gas fields, LNG terminals and other cross border gas sourcing points. GAIL is also expanding its business to become a player in the International Market. Today, GAIL's Business Portfolio includes * 7,700 km of Natural Gas high pressure trunk pipeline with a capacity to carry 157 MMSCMD of natural gas across the country * 7 LPG Gas Processing Units to produce 1.2 MMTPA of LPG and other liquid hydrocarbons

* North India's only gas based integrated Petrochemical complex at Pata with a capacity of producing 4,10,000 TPA of Polymers * 1,922 km of LPG Transmission pipeline network with a capacity to transport 3.8 MMTPA of LPG * 27 oil and gas Exploration blocks and 3 Coal Bed Methane Blocks * 13,000 km of OFC network offering highly dependable bandwith for telecom service providers * Joint venture companies in Delhi, Mumbai, Hyderabad, Kanpur, Agra, Lucknow, Bhopal, Agartala and Pune, for supplying Piped Natural Gas (PNG) to households and commercial users, and Compressed Natural Gas (CNG) to the transport sector * Participating stake in the Dahej LNG Terminal and the upcoming Kochi LNG Terminal in Kerala * GAIL has been entrusted with the responsibility of reviving the LNG terminal at Dabhol as well as sourcing LNG * GAIL Gas Limited, a wholly owned subsidiary of GAIL (India) Limited, was incorporated on May 27, 2008 for the smooth implementation of City Gas Distribution (CGD) projects. GAIL Gas Limited is a limited company under the Companies Act, 1956. * Established presence in the CNG and City Gas sectors in Egypt through equity participation in three Egyptian companies: Fayum Gas Company SAE, Shell CNG SAE and National Gas Company SAE.

* Stake in China Gas Holding to explore opportunities in the CNG sector in mainland China * A wholly-owned subsidiary company GAIL Global (Singapore) Pte Ltd in Singapore

HISTORY
GAIL (India) Ltd. (erstwhile Gas Authority of India Ltd), India's principal gas transmission and marketing company, was set up by the Government of India in August 1984 to create gas sector infrastructure for sustained development of the natural gas sector in the country. The 2800-km Hazira-Vijaipur-Jagdishpur (HVJ) pipeline became operational in 1991. During 1991-93, three LPG plants were constructed and some regional pipelines acquired, enabling GAIL to begin its regional gas distribution in various parts of India. GAIL began its city gas distribution in Delhi in 1997 by setting up nine CNG stations, catering to the city's vast public transport fleet.In 1999, GAIL set up northern India's only petrochemical plant at Pata.GAIL became the first Infrastructure Provider Category II Licensee and signed the country's first Service Level Agreement for leasing bandwidth in the Delhi-Vijaipur sector in 2001,

through its telecom business GAILTEL. In 2001, GAIL commissioned world's longest and India's first Cross Country LPG Transmission Pipeline from Jamnagar to Loni.GAIL today has reached new milestones with its strategic diversification into Petrochemicals, Telecom and Liquid Hydrocarbons besides gas infrastructure. The company has also extended its presence in Power, Liquefied Natural Gas regasification, City Gas Distribution and Exploration & Production through equity and joint ventures participations. Incorporating the new-found energy into its corporate identity, Gas Authority of India was renamed GAIL (India) Limited on November 22, 2002.

INTREGATED OFFSITE PLANT & STORAGE (IOP & S)

INTRODUCTION TO POWER PLANT

Power Plant in U. P. Petrochemical Complex comprises 3 Nos. Utility Boilers each having Steam Generating Capacity of 120 TPH at MCR, at pressure 106 Kg/Cm2 (g) 510 oC. The Steam Generated from all these boilers is utilised for production of Electrical Power in 2 Nos. of Turbo Generators having Generating Capacity of 15.5 MW(Extraction type) & 25.6 MW(Condensing type) in addition to meeting demand for process steam requirement in different section of the complex . The high pressure steam (106 Kg/Cm2 (g) ) produced from all the 3 boilers is connected to a common header from where steam is fed separately to 2 nos. of steam turbines , serving as prime mover to rotate 2 nos. of generators. Normally, these boilers are meant for producing steam at very high pressure (105 Kg/Cm2) but depending on process requirement this VHP steam is led down to high pressure (40 Kg/Cm2) , Low medium pressure (8.0 Kg/Cm2) and Low pressure at 4.0 Kg/Cm2.

UTILITY BOILER

A- Construction Details:
Make Boiler Designation : M/s BHPV : F 26 Where F- Stands for : Furnace : Width of furnace in feet : Length of furnace in feet : Vertical Unit. :I.D of upper drum in inch. : Diameter of Bank tube in inch 36 : ID. of Lower drum in inch 17.3 VU 60 2 60 36

17.3
26 VU 60 2

Location Boiler Type

: Semi out Door : Natural Circulation, BIDrum, Front Wall Fired Forced Draft Furnace, Radiant Closed Bottom

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Suitable for Oil/Gas Firing Fuel : Rich Gas : Lean Gas : Combination of Blended fuel oil & Rich Gas.

GENERAL DESCRIPTION OF BOILER

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The steam generator is a natural circulation water tube design arranged for forced draft firing . Basically it is a two drum vertically bent tube arrangement with water cooled furnace walls combined with convective boiler bank surfface. The furnace is specifically designed to suit for 10% excess air operation for gas firing . The complete furnace section is of the welded wall type arranged as a gas and pressure tight envelope which eliminates the problem of casing corrosion and cumbersome refractory maintenance , besides this provides structural rigidity for the unit . The complete steam generator is of the bottom supported design resting on concrete pedestals . The conservatively sized upper and lower drums are connected by the bank tubes . The steam drum is provided with simple and efficient drum internals ,resulting in high steam quality at all loads of boiler outputs . Unheated downcomers are located in the boiler bank sides. The boiler bank tubes are arranged in line for best heat absorption , minimum tube draft loss and for easy inspection and cleaning . Required accessibility is provided at the front & rear side of the boiler bank convective surface . Adequate peepholes are also provided to watch the flame. The feed water from economiser is fed into the steam drum. Circulation is maintained in the boiler bank through the downcomers . From the bottom drum, water flows through the heat absorbing furnace tubes and back into steam drum .After separation of moisture in the steam drum the saturated steam flows into the superheater . The superheater system has two sections. They are radiant platen pendent section (arranged at the outlet of furnace) and the final superheater adjacent to platen section. A desuperheater is provided in-between the two sections in the connective links for controlling the superheater temperature over the wide load range . The location and selection of superheater is so chosen that the

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specified temperature of superheater achieved between 30 to 100% MCR load of the boiler . The firing system consists of 4 No. of burners designed for gas firing located in the font wall . Gas igniters are provided for lighting the burner . The flame scanning system is provided to monitor the main flame condition in the furnace. 1 No. Forced draft fan with dual drive (motor + steam turbine ) will supply the complete combustion air at the required pressure for the boiler. A bare tube in line economiser is provided as the last heat recovery section. The complete integral piping , valves and fitting, air and gas ducting, all refractory and insulation materials are provided. Feed water is supplied to the steam drum from the feed storage tank through feed line. The water side of the steam drum is connected with lower drum through boiler bank tubes . Furnace side walls inlet headers are supplied with water from lower drum through supply tubes. The steam water mixture generated in the side walls are collected in the side wall outlet headers and from where it is discharged into the drum through a system of riser tubes. Boiler water from the lower drum is fed into the front walls through floor panels and discharged into steam drum as steam water mixture . Likewise rear wall receives the boiler water from lower drum and discharges to the steam drum. B - ECONOMISER The purpose of the economiser is to preheat the boiler feed water before it is introduced into the steam drum, and to recover some of the heat from the fuel gases leaving the boiler.

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The economiser is located in the second pass of the boiler. Each section is composed of a number of parallel tube circuits, arranged in horizontal rows. All tube circuits originate from inlet header and discharge into outlet header. Feed water is supplied to the economiser inlet headerfrom FEED CONTROL STATION. The feed water flow is upward or downward through the economiser that is in counterflow to the hot fuel gases . Most efficient heat transfer is thereby accomplished . Any chance of steam generation within the economiser is eliminated . From the outlet header the feed water is led to the drum. Before starting up the boiler, the economiser should be inspected externally and if necessary cleaned . Especially if the installation is new, accumulation of erection material is not unusual. Large debris should be removed manually , followed by the washing down the economiser banks by means of hose and water. All joints in the economiser casing should be examined occasionally for tightness in order that air in filtration be kept to minimum. Insulation should be kept in good condition. C - SUPERHEATER It is non drainable superheater , pendant type . The superheater coils are suspended below the superheater header. No. of coils in Primary Super Heater (PSH ) - 13 No. of coils in Final Super Heater (FSH ) 47

D - DESUPERHEATER Desuperheater are provided in the steam line between PSH & FSH to permit reduction of steam temperature when necessary and to maintain the temperature at design values within the limits.

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Temperature reduction is accomplished by injecting spray water into the path of the steam through a nozzle . The spray water source is from the boiler feed water system. It is essential that the spray water be chemically pure to avoid contamination of main steam. E- BURNER 4 nos. of Dual Fuel Burner per boilers are mounted on common windbox . The windbox is designed in such a manner that combustion air is uniformly distributed to all the burners. The combustion air entry to the burner is through air register which is controlled by pneumatically operated air cylinder. The dual Fuel Burner is Fitted with 1 No. of oil gun with steam atomiser tip assembly and 8 Nos. of Gas Poker Assembly. The ignition system which is supplied along with burner is capable of lighting liquid as well as gaseous fuel on giving light up command to ignitor . Pilot flame presence indication will be giving to the Burner Management System . In turn BMS will give a signal to open gas valve. Thereafter Main Gas Flame will be detected by flame scanners system. The flame scanners system shall provide the continuous monitoring of the flame inside the furnace which shall provide safety to the boiler. In the event of Flame outage of individual burner the flame monitoring system shall give signal to open or to close gas valves together with other interlocks for safe tripping of the burners isolation valves. In the event of all four burners flame failure it will trip master fuel trip valve. The flame monitoring system is provided with self check facility so that spurious signals are eliminated and reliable performance of the burner is guaranteed. FD FAN :

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Centrifugal Single Suction Fans are being used to handle Clean Air . The spiral Casing converts part of kinetic energy of the fluid into a Static Pressure . the Fan output is usually controlled by adjustable inlet dampers or by varying the speed of the Fan either by means of hydraulic couplings or by any suitable speed control device .The fan is driven by motor/prime mover through coupling. OPERATING PROCEDURES FOR BOILER A - Preparation 1.Inspect the boiler prior to start. Chack that (a) All foreign material has been removed. (b) All doors are closed. ( c ) Starting equipments are ready. (d) Interlocks are OK. (e) Individual valves of burners are closed. 2.Close the Following Valves. (a) Feed water regulating valve (b)All drain valves of boiler, water walls and Economizer. (c)Desuperheater control valves. Open the Following Valves. (a) Drum Air Vents. (b)SH Air Vents. (c)SH drain Valves

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(d)Main steam line drain valve. (e)Start up vent valve. (f)Isolation valves on both sides of desuperheater control valve. (g)All instrument and control connections to the boiler. 3.Check the Following Eqts for adequate Lubrication & Cooling Water Flow. (a)Boiler Feed Pump. (b)FD Fan. 1. Put all automatic Control equipments on Manual Control. 2. Check that all Control equipments are ready for service. Manually operate all sequential trips and see that the emergency fuel trips function properly. B- LIGHT UP.
a)

Take water into Steam Drum and maintain Drum Level Normal.

b) Close Inlet vanes of FD Fan. c) Open inlet damper of Air duct. d) Open inlet damper of Chimney . e) Start FD Fan. f) Increase Air Flow more than 30% of MCR. g) Light the Lower burner one at a time .

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h) i)

Close Drum Air vents when Drum pressure reaches 2 Kg/Cm2. Take other Burners in line and raise the drum pressure slowly as per start up curve

j)

Connect the boiler with the Header when steam pressure is 105 kg/Cm2.

k) Close main steam drain and SH drains. l) Inject Chemicals into D/A and drum to maintain C- SHUT- DOWN a) Start reducing boiler load gradually. Reduce the firing rate in line with reducing the steam flow. b) Shut-Down the Burners one at a time, Starting with the upper elevation . c) All fires should be out when the boiler is off the line. d) Run the Fans for at least 10 minutes after Shutting down. e) Maintain the water level in drum .
f)

When the drum pressure comes down to 2 Kg/Cm2.

STEAM TURBINE
A turbine is a rotary engine that extracts energy from a fluid flow and converts it into useful work. The simplest turbines have one moving part, a rotor assembly, which is a shaft or drum with blades attached. Moving fluid acts on the blades, or the blades react to the flow, so that they move and impart rotational energy to the rotor. Early turbine examples are windmills and water wheels.

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Gas, steam, and water turbines usually have a casing around the blades that contains and controls the working fluid. Credit for invention of the steam turbine is given both to the British Engineer Sir Charles Parsons (18541931), for invention of the reaction turbine and to Swedish Engineer Gustaf de Laval (18451913), for invention of the impulse turbine. Modern steam turbines frequently employ both reaction and impulse in the same unit, typically varying the degree of reaction and impulse from the blade root to its periphery. A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion. It has almost completely replaced the reciprocating piston steam engine primarily because of its greater thermal efficiency and higher power-to-weight ratio. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible process. There are several classifications for modern steam turbine.

Type of Turbines(A)Based on operation

Impulse Turbines: It has fixed nozzles that orient the steam flow into high speed jets. These jets contain significant kinetic energy, which the rotor blades, convert into shaft rotation as the steam jet changes direction. A pressure drop occurs across only the stationary blades, with a net increase in steam velocity across the stage. As the steam flows through the nozzle its

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pressure falls from inlet pressure to the exit pressure (atmospheric pressure, or more usually, the condenser vacuum). Due to this higher ratio of expansion of steam in the nozzle the steam leaves the nozzle with a very high velocity. The steam leaving the moving blades is a large portion of the maximum velocity of the steam when leaving the nozzle. The loss of energy due to this higher exit velocity is commonly called the "carry over velocity" or "leaving.

Reaction Turbines: In this the rotor blades themselves are arranged to form convergent nozzles. This type of turbine makes use of the reaction force produced as the steam accelerates through the nozzles formed by the rotor. Steam is directed onto the rotor by the fixed vanes of the stator. It leaves the stator as a jet that fills the entire circumference of the rotor. The steam then changes direction and increases its speed relative to the speed of the blades. A pressure drop occurs across both the stator and the rotor, with steam accelerating through the stator and decelerating through the rotor, with no net change in steam velocity across the stage but with a decrease in both pressure and temperature, reflecting the work performed in the driving of the rotor.

(B)Based on Steam Supply and Exhaust Conditions

Noncondensing or backpressure turbines are most widely used for process

steam applications. The exhaust pressure is controlled by a regulating valve to suit the needs of the process steam pressure.
Condensing turbines exhaust steam is in a partially condensed state,

typically of a quality near 90%, at a pressure well below atmospheric to a condenser.

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In a reheat turbine, steam flow exits from a high pressure section of the

turbine and is returned to the boiler where additional superheat is added. The steam then goes back into an intermediate pressure section of the turbine and continues its expansion.
In an extracting type turbine, steam is released from various stages of the

turbine, and used for industrial process needs or sent to boiler feedwater heaters to improve overall cycle efficiency. Extraction flows may be controlled with a valve, or left uncontrolled.
Induction turbines introduce low pressure steam at an intermediate stage to

produce additional power.

Principle of Operation
1 The motive power in a steam turbine is obtained by the rate of change in momentum of a high velocity jet of steam impinging on a curved blade which is free to rotate. This jet of steam impinges on the moving vanes or blades, mounted on a shaft. Here it undergoes a change of direction of motion which gives rise to a change in momentum and therefore a force. The interior of a turbine comprises several sets of blades. One set of stationary blades is connected to the casing and one set of rotating blades is connected to the shaft. The sets intermesh with certain minimum clearances, with the size and configuration of sets varying to efficiently exploit the expansion of steam at each stage.

Operation and Maintenance

When warming up a steam turbine in order to avoid slugging nozzles and blades inside the turbine with condensate on start-up which can break these components from impact. The blades were designed to handle steam, not water. The main steam stop valves have a bypass line to allow superheated steam to slowly bypass

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the valve and proceed to heat up the lines in the system along with the steam turbine..

Steam Turbine Components

The components of Steam Turbine are:

Blades Rotors Casings Seals Nozzles.

Steam turbines consist of circularly distributed stationary blades called nozzles which direct steam on to rotating blades or buckets mounted radially on a rotating wheel. In a steam turbine nozzles apply supersonic steam to a curved blade. The blade whips the steam back in the opposite direction, simultaneously allowing the steam to expand a bit.Typically, the blades are short in proportion to the radius of the wheel, and the nozzles are approximately rectangular in cross section.

STEAM TURBINE GENERATOR (STG # 1)

Vendor Type Capacity No. of Stages HP (Impulse +Reaction) : : M/s BHEL Hyderabad. EHNG 40/32 3.

: 15.5 MW. : 17 :1+6

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LP (Impulse +Reaction) Turbine Speed

:1+9 : 8500 rpm.

Reduction Gear Output Speed 3000 rpm. Steam Pressure Steam Temperature Wheel Chamber Extraction Pressure Extraction Flow Exhaust Pressure Exhaust Flow Maxm Steam Flow : 105 Kg/Cm2 : 500 oC : 75.8 Kg/Cm2 : 41.0 Kg/Cm2 : 55 TPH : 5.00 Kg/Cm2 : 75 TPH : 130 TPH

STG # 2
Vender Type Capacity No. of Stages Impulse Reaction : M/s BHEL : Full Condensing

: 25.6 MW : 48 :1 : 47

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Turbine Speed Steam Pressure Steam Temperature Steam Flow

: 3000 rpm : 105 Kg/Cm2 : 500 oC : 91 TPH (for full Load)

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PROTECTIVE EQUIPMENTS (a)EMERGENCY STOP VALVE : It is a protection eqt.The emergency stop valve is the fundamental shut off organ in the live steam line . In event of a disturbance , it cuts off steam supply to the turbine in a minm time . It will be in the closed position when the turbine is at stand still position . (b)OVER SPEED TRIP : It is a protection system against un acceptable over speed . The over speed trip shuts down the turbine when the permissible turbine speed is exceeded by more than 5%. If the turbine speed rises to the set tripping speed the centrifugal force of the pin in the over speed trip bolt over comes the force of the compression spring . The trip bolt moves a few mm out of the shaft , thereby striking the pawl of the automatic trip. This opens the trip oil circuit so that the emergency stop valve and control valves close, thus shutting down the turbine immediately (c)EMERGENCY TRIPPING DEVICE : It is a protection device . In the event of a disturbance , the emergency tripping device serves for admitting emergency trip oil and causes closing of the ESV and separation of the turbine from the steam supply .

(d)Control Valves
The control valves are opened and closed in order to adjust the through put of steam to give the required power out put from the turbine . Depending on the power required , the control valves are opened or closed in a specific sequence.

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When the turbine is at rest, the springs keep the crossbar in its lowest and valves are forced on to their seat by the pressure of steam . A control pulse from the governor causes the actuator to pull the arm downwards , the raising the stems and lifting the crossbar . The valves then lift in a sequence determined by the different lengths of the spacer bushes in the crossbar .

POWERGENERATIONTHROUGH STGsPresently the Maximum requirement of Electrical power for the complex is around 32 MW. This demand of 32 MW power requirement in met by 2 Steam Turbo Generators . 2 Nos. of Generators having capacity of 15.5 MW & 25.6 MW are separately coupled with steam turbines, serving as prime movers. Power Generated by these Generators is at 11 KV . It is further stepped up to 33 KV through transformers which is synchronised with the 33 KV grid. This power at 33 KV is then stepped down through the transformers to 6.6 KV & 415 KV to run HT motors and L.T. motors of the complex.

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DOWN STREAM
HIGH DENSITY POLY ETHYLENE (HDPE) & LOW LINEAR DENSITY POLY ETHYLENE (LLDPE)

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BRIEF DESCRIPTION OF HDPE PROCESS

Catalyst system
To initiate any polymerization reaction, catalyst is necessary. The catalyst system for Polyethylene is based on Ziegler-Natta catalysts. This system consists of a catalyst-co catalyst pair. Main catalyst - Halides or other derivatives of transition metals in group IV-VIII of periodic table. (In our plant it is the PZ catalyst which is based on ticl4). Co catalyst - Alkyls of Group I-III metals. (In our plant it is TEAL i.e. Try Ethyl Aluminum)

Polymerization Raw materials

The raw materials used in the production of HDPE and their roles is as, Ethylene This is the basic monomer which forms the backbone of HDPE chain. Catalyst This initiates the polymerization reaction. Hydrogen This helps in termination of polymer chain. Hence this controls the molecular weight. So Hydrogen is used to control MFR. The control of Hydrogen feed is done based on Hydrogen / Ethylene ratio. This ratio varies as per grade because each grade has different MFR. Butene-1 / Propylene These two are co-monomers. They take part in reaction along with Ethylene and form side branches. The loading of co-monomer decides density of polymer. Hexane This is inert reaction medium. This helps in removal of enormous amount of heat of polymerization.

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Polymer formation diagram-

Catalyst (PZ, AT) (

Catalyst preparation p

C Catalyst soln

P Polymerization

Raw material like C2, H2, Bu-1, Propylene P

P Polymer slurry

Pure and dry hexane h

Mother liquor recycle r

Separation & D Drying

D Dry powder Mother liquor l

Hexane r recovery
Crude hexane from IOP f

P Pelletizer

Recovered hexane h

G G-Lex pellets for bagging

Low polymer h handling F Flaker unit

M Molten wax L LP Flakes

L LP pits

L LP wax to flaker

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Operation
The polymerization reaction is highly exothermic. It gives out enormous amount of heat. This heat needs to be taken out immediately and effectively to avoid run away reactions. The reactors have three modes of heat removal, Overhead coolers the un-reacted gas from reactor is taken to overhead cooler. The hexane content in the gas is cooled and separated. The cooled gas is again bubbled from the bottom of the reactor. Along with agitators, this helps in preventing the slurry from settling. The condensed hexane is also fed back to the reactor. Slurry coolers at high loads, some portion of slurry is also taken out from the bottom of the reactors. It is circulated through coolers and fed back to the reactors. Jackets - Each reactor has jacket with cooling water running through it. Feed of Hydrogen to the reactor is most critical part of the polymerization. It needs to be accurately controlled. Each reactor is equipped with on line Process Gas Chromatographs (PGC) for this purpose. A small sample of un-reacted gas from the reactor is continuously fed to the PGC. PGC analyses the Hydrogen and Ethylene content of the stream. Special programs on the MAPS convert the % to ratio of Hydrogen to Ethylene. Hydrogen valve opening is controlled by MAPS Programme

Separation
The polymer slurry, after degassing, is fed to the centrifuge. The centrifuge separates the polymer powder from hexane. The wet cake of polymer is fed to dryer. The hexane decanted contains some amount of low polymer formed during polymerization and is called mother liquor. The wet cake is dried in rotary dryer. Some portion of the mother liquor is recycled back to the reactors. Remaining mother liquor is sent to hexane recovery section of purification of hexane.

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Drying
The wet cake from centrifuge is fed to rotary dryer. It has hexane content of 30% by weight. $Dryer uses two drying media, Low pressure steam running through the inner pipe inside the dryer. This is indirect heating. Hot nitrogen fed to the dryer coming in contact with powder. This is direct heating. $The hot nitrogen coming from dryer is cooled and scrubbed with hexane to wash off any entrained powder. It is again heated and fed back to dryer. The dry powder (with hexane content of 0.2% wt or lower) is conveyed to hopper by nitrogen

Extruder

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The dry powder from dryer is taken to a intermediate hopper. Before sending to extruder, various additives are mixed with the powder. The blend of powder and additives is melted in the extruder barrel. The melt is forced through a die having number of holes to give thin noodle like strands. A cutter assembly, rotating very close to the face of the die, cuts the strands to pellets. The pellets are conveying by air to various storing silos. From silos, the pellets are sent for bagging

Hexane recovery
The mother liquor decanted from centrifuge is fed to this section. The low polymer in mother liquor is separated in a stripper. Pure hexane vapors from stripper top are recovered, condensed and dehydrated. The pure hexane is stored in tanks and put in re-use. The low polymer concentrate recovered from stripper bottom is subjected to flashing to recover maximum hexane from it. The low polymer is then dumped to pits. After solidification, low polymer blocks are cut out. These are processed in flaker plant to form flakes.

Utilities
Various utilities / auxiliary services used in the plant are, Brine system HP steam LP steam Nitrogen Process water Instrument air Cooling water Electric power

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Caustic soda

MECHANICAL SEALGeneral Classifications Seals may be generally sub-divided into : (A)Dynamic Seals (B)Static Seals The primary purpose of seals is to prevent ingress of unwanted contaminants and to prevent egress of any internal sustance whether it be gas or liquid for containment or lubrication. The majority of applications are in areas where the substance retained is a lubricant and the purpose of the seal is to ensure that it stays where it is put. In simple terms, external seals have two main functions: to prevent lubricating oil from leaking out, and, to prevent dust, water, and other contaminants from entering the bearing. When selecting a seal, the following factors need to be taken into consideration: the type of lubricant (oil or grease), seal peripheral speed, shaft fitting errors, space limitations, seal friction and resultant heat increase, and cost. Dynamic seals can be used with either rotary or reciprocating motions. A separate group of dynamic seals comes under the heading others. These seals are indeed statistically attached to the counterfaces and the limited motion is fully taken up by the seal material itself. Examples of the latter would be bellows and the diaphragms. Apart from Static and dynamic, the Sealing devices for rolling bearings fall into two main classifications: (a)Contact Seals. (b)Non-contact Seals.

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a.

Contact seals: Contact seals accomplish their sealing action through the contact pressure of a resilient part of the seal (the lip is often made of synthetic rubber) and the sealing surface. Contact seals are generally far superior to non-contact seals in sealing efficiency, although their friction torque and temperature rise coefficients are higher. b. Non-contact seals: Non-contact seals utilize a small clearance between the shaft and the housing cover. Therefore friction is negligible, making them suitable for high speed applications.

PUMP

Pump is the machine that lifts liquids, moves them from place to place,pressurizes them for a number of task converting mechanical energy from a prime mover such a motor, turbine etc. The reliability & availability & efficiency of the different type of pumps depends a lot on the behavior of these machines. Under this system, the pumps can be classified as: DYNAMIC TYPE In which the energy is continuously added to increase the fluid passes through a volute while increases the pressure. DISPLACEMENT TYPE

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In which the energy is periodically added by application of force to one or more moveable boundaries of any desired number of enclosed, fluid containing volumes, resulting into direct increase in pressure upto the valve required to move the fluid thru valves or ports into discharge line.

Classification of pumps -

P D C A S I N G L E X I A SM L T U A L GT EI S T A E Y N N T A R

U M I F

P I S G M A I X G L P L E E D F D S OU L UC O BT W / LI O E N S R L A C E M E N T

I C D U

G S E I N

O I MP

PE

EN

L I LM E O P R PE

LE

LN E I R M S

EP

ME

LI

LO E P R C E

LN O I SM

EP

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Centrifugal pump (dymamic type)

CONSTRUCTION FEATURES Centrifugal pump essentially consists of: Impeller Shaft with sleeve Casing ( Volute / diffuser) Support bearings & bearing housings Wear rings Pump sealing (gland packing / mech seal) Coupling Prime movers (Electric motor / turbines / engines)

Liquid flow path inside a centrifugal pump

A centrifugal pump has two main components: I. A rotating component comprised of an impeller and a shaft II. A stationary component comprised of a casing, casing cover, and bearings.

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General components of Centrifugal Pump

Stationary Components
1. Casing
Casings are generally of two types: volute and circular. The impellers are fitted inside the casings. 1. Volute casings build a higher head; circular casings are used for low head and high capacity.

A volute is a curved funnel increasing in area to the discharge port. As the area of the cross-section increases, the volute reduces the speed of the liquid and increases the pressure of the liquid. One of the main purposes of a volute casing is to help balance the hydraulic pressure on the shaft of the pump .Double- volute casings are used when the radial thrusts become significant at reduced capacities.

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2. Circular casing have stationary diffusion vanes surrounding the impeller

periphery that convert velocity energy to pressure energy. Conventionally, the diffusers are applied to multi-stage pumps.

The casings can be designed either as solid casings or split casings. Solid casing implies a design in which the entire casing including the discharge nozzle is all contained in one casting or fabricated piece. A split casing implies two or more parts are fastened together.

2.

Suction and Discharge Nozzle

The suction and discharge nozzles are part of the casings itself. They commonly have the following configurations. 1. Side suction/Top discharge - The suction nozzle is located at the end of, and concentric to, the shaft while the discharge nozzle is located at the top of the case perpendicular to the shaft. This pump is always of an overhung type and typically has lower NPSHr because the liquid feeds directly into the impeller eye. 2. Top suction Top discharge nozzle -The suction and discharge nozzles are located at the top of the case perpendicular to the shaft. This pump can either be an overhung type or between-bearing type but is always a radially split case pump. 3. Side suction / Side discharge nozzles - The suction and discharge nozzles are located at the sides of the case perpendicular to the shaft. This pump can have either an axially or radially split case type.

3. Seal Chamber and Stuffing Box

Seal chamber and Stuffing box both refer to a chamber, either integral with or separate from the pump case housing that forms the region between the shaft and casing where sealing media are installed. When the sealing is achieved by means of a mechanical seal, the chamber is commonly referred to as a Seal Chamber.

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When the sealing is achieved by means of packing, the chamber is referred to as a Stuffing Box

Gland: The gland is a very important part of the seal chamber or the stuffing box. It gives the packing or the mechanical seal the desired fit on the shaft sleeve. It can be easily adjusted in axial direction. The gland comprises of the seal flush, quench, cooling, drain, and vent connection ports as per the standard codes like API 682. Throat Bushing: The bottom or inside end of the chamber is provided with a stationary device called throat bushing that forms a restrictive close clearance around the sleeve (or shaft) between the seal and the impeller. Throttle bushing refers to a device that forms a restrictive close clearance around the sleeve (or shaft) at the outboard end of a mechanical seal gland. Internal circulating device refers to device located in the seal chamber to circulate seal chamber fluid through a cooler or barrier/buffer fluid reservoir. Usually it is referred to as a pumping ring. Mechanical Seal is a type of seal utilized in rotating equipment, such as pumps and compressors. When a pump operates, the liquid could leak out of the pump between the rotating shaft and the stationary pump casing. Since the shaft rotates, preventing this leakage can be difficult.

4. Bearing Housing
The bearing housing encloses the bearings mounted on the shaft. The bearings keep the shaft or rotor in correct alignment with the stationary parts under the action of radial and transverse loads. The bearing house also includes an oil reservoir for lubrication, constant level oiler, jacket for cooling by circulating cooling water.

Rotating Components

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1. Impeller
The impeller is the main rotating part that provides the centrifugal acceleration to the fluid. They are often classified in many ways. Based on major direction of flow in reference to the axis of rotation Radial flow Axial flow Mixed flow Based on suction type Single-suction: Liquid inlet on one side. Double-suction: Liquid inlet to the impeller symmetrically from both sides. Based on mechanical construction Closed: Shrouds or sidewall enclosing the vanes. Open: No shrouds or wall to enclose the vanes. Semi-open or vortex type

Impeller types

Impeller type

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Closed impellers require wear rings and these wear rings present another maintenance problem. Open and semi-open impellers are less likely to clog, but need manual adjustment to the volute or back-plate to get the proper impeller setting and prevent internal re-circulation. Vortex pump impellers are great for solids and "stringy" materials but they are up to 50% less efficient than conventional designs. The number of impellers determines the number of stages of the pump. A single stage pump has one impeller only and is best for low head service. A two-stage pump has two impellers in series for medium head service. A multi-stage pump has three or more impellers in series for high head service.

Wear rings: Wear ring provides an easily and economically renewable leakage joint between the impeller and the casing. Clearance becomes too large the pump efficiency will be lowered causing heat and vibration problems.

Shaft: The basic purpose of a centrifugal pump shaft is to transmit the

torques encountered when starting and during operation while supporting the impeller and other rotating parts. It must do this job with a deflection less than the minimum clearance between the rotating and stationary parts. Shaft Sleeve: Pump shafts are usually protected from erosion, corrosion, and wear at the seal chambers, leakage joints, internal bearings, and in the waterways by renewable sleeves. The sleeve shall be sealed at one end. The shaft sleeve assembly shall extend beyond the outer face of the seal gland plate. Coupling: Couplings can compensate for axial growth of the shaft and transmit torque to the impeller. Shaft couplings can be broadly classified into two groups: rigid and flexible. Rigid couplings are used in applications

41

where there is absolutely no possibility or room for any misalignment. Flexible shaft couplings are more prone to selection, installation and maintenance errors. Flexible shaft couplings can be divided into two parts-

Elastomeric couplings use either rubber or polymer elements to achieve flexibility. These elements can either be in shear or in compression. Tire and rubber sleeve designs are elastomer in shear couplings; jaw and pin and bushing designs are elastomer in compression couplings.

Non-elastomeric couplings use metallic elements to obtain flexibility. These can be one of two types: lubricated or nonlubricated.

POSITIVEDISPLACEMENT PUMP (RESIPROCATING TYPE)

WORKING PRINCIPLE In a reciprocating pump, a piston / plunger makes reciprocating motion inside a cylinder. The pump functions by sucking the fluid through suction valves into the cylinder during the backward stroke of the piston / plunger. The kinetic energy of the fluid is increased during the subsequent forward stroke of the piston / plunger. The fluid is then delivered to the high pressure discharge manifold when the desired pressure values (discharge pressure) are attained. Reciprocating pumps are either single acting or double acting and they are also run in parallel (many pumps are operated in one crank shaft) to increase the quantity at the same pressure.

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LLDPE
REACTION AREA
Solvent (SH) is recycled to the reaction area from the reflux drum of the HB Column in the Solvent Recovery Area. The temperature of this solvent stream is approximately 175oC and is cooled to 31oC by a series of heat exchangers which includes the Process Exchanger and the Recycle Coolers. First, cooling in the Process Exchanger will reduce the recycle solvent temperature to approximately 155oC. The heat from this stream is used to warm the feed to one of the distillation columns thereby increasing the energy efficiency of the operation. Further cooling is provided with a Recycle SH Air Cooler in series with a Recycle SH water Cooler. The use of Recycle SH Air Cooler minimizes cooling water demand. There are two reactor modes which are normally used. 1) #1 Reactor mode 2) 31 Reactor mode The polymerization reaction is highly exothermic, releasing approximately 93.7 MJ of heat per kg mol of monomer or comonomer reacted. All reactor modes operate adiabatically and therefore there is a substantial increase in the temperature of the reaction mixtures through the reactor system.

RECYCLE AREA
The solvent and steam condensed in the Solvent Vapour Condenser from the overhead of the Stripper is collected in a Decanter. In order to facilitate water removal from the solvent, the Decanter is designed with a coalescer. Solvent leaving the Decanter is relatively dry, containing dissolved water but no separate liquid water phase. The saturation level for water in SH at 35oC is about 100 ppm

43

by weight. This stream is pumped to the LPS Hold Up Tank (HUT) in the LPVR area.

Polymer formation flow diagram

EXTRUSTION \FINISHING AREA

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Polymer from the bottom of the LPS is fed directly into the feed hopper of the Main Extruder. The function of the Main Extruder is to pressurize the polymer and feed it to the Melt Cutter or Pelletizer, which produces uniform pellets of the polymer. In the feed section of the Main Extruder, there is a tendency for gas to build up at the rear of the first extruder screw flite. On low MI resins, at high screw speeds, the vapour pocket formed Solid additives can be added to the main extruder with the aid of the satellite extruder. The Melt Cutter consists of a die plate on which rotates a set of knife blades which cut the emerging polymer strands into uniform sized pellets. A flow of water circulates through the cutter housing to first quench and then convey the cut pellets away from the cutter. From the melt cutter, the pellets are conveyed to a Delumper that segregates large lumps of polymer into a waste hopper. Generally, large lumps are produced only during startup of the extruder/cutter system. The Melt Cutter consists of a die plate on which rotates a set of knife blades which cut the emerging polymer strands into uniform sized pellets.

BUTENE-1
process can be divided into following areas: 1. Catalyst section. 4. Distillation section. 2. Reaction section. 5. Storage section. 3. Evaporation section.

FLOW DIAGRAM OF BUTENE-1

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46

UPSTREAM GAS PROCESS UNIT (GPU) & GAS CRACKER UNIT (GCU)

47

GAS SWEETENING UNIT

Sweetening means removal of acid from gases like H2S & CO2. The HVJ gas is received from ONGC contains CO2 (5.52% by volume) & H2S (4ppm). The gas forms the feedstock to the C2-C3 recovery unit where cryogenic conditions prevail & if the CO2 component of the gas is not received. It will freeze at such a low temp. Gas sweetening plant uses DEA (Di Ethanol Amine) as a solvent for removing CO2 in the natural gas by chemical absorption.

ABSORPTION SECTION
Natural gas coming from HVJ is treated in two parallel high pressure absorbers. The gas is fed to the absorber column at a pressure of 52 kg/cm2 & temp 30 C. This gas is counter currently treated with DEA solvent (40% by weight) which is fed from the top of the column. The absorber column contains 30 valve trays. The treated gas leaves from top of the column at 45 C & contains less then 50 ppm of CO2.

TREATED GAS WATER WASH & COOLING

The treated gas from absorber column is counter currently washed with water in water wash column equipped with ball rings to remove the DEA carried over the gas. The DEA solution in water is removed from the bottom of this column & sent to the rich amine flash drum. The treated gas is cooled to 40 C & leaves the unit at pressure 50 kg/cm2.

48

RICH AMINE CIRCUIT:

The rich amine from the absorber bottom & the water wash column are sent to rich amine flash drum. The rich amine flash drum is operated at 6.5 kg/cm2 & 70 C. Most of the hydrocarbons are co-absorbed in DEA solution is removed in this drum & sorted to the plant fuel gas system.

AMINE REGENERATION:
The rich amine solution from the flash drum enters the regenerator column through the rich lean amine exchanger at 110 C. In the regenerator the solvent DEA is stripped off CO2 using low pressure steam in the column reboilers. The column has 21 valve trays. The top two trays are used to minimize DEA carryover with the CO2. This column operates at 2kg/cm2. The top temp is 97 C & the temp at the bottom is around 126 C. The lean amine is withdrawn from bottom of the column & is sent to storage after being cooled to 45 C in rich lean amine exchanger & then by cooling water. Vapors from the top of the regenerators are condensed in the regenerator overhead condenser & taken in to Regeneration reflux drum. The uncondensed gases mainly CO2 are vent to atmosphere at a safe location & the condensed liquid is pumped back as reflux to the column.

AMINE STORAGE:
The lean amine from regenerator is sent to amine storage tank from where it is pumped to the absorbers. The amine tank is blanketed with N2 to prevent solvent degradation with O2.

AMINE FILTERATION:

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A stream of stored amine solution is continuously sent to the filteration package by amine filteration pump. DEA solvent filteration is required to remove all the dissolved hydrocarbons, scales & solvent degradation products that can cause corrosion & foaming. Levels of filteration may be asa) Precoat filter consisting of cellulose b) Activated carbon filter which removes corrosion products c) Cartridge filter which removes any carbon particles

ANTIFOAM INJECTION PACKAGE:

Antifoam facilities are provided to overcome foaming problems in the absorber. The antifoam solution is an aqueous solution of silicon oil. This is injected to the suction of amine charge pumps.

AMINE DRAIN RECOVERY:

All the solvent drains are removed in an underground amine sump pump.

C2/C3 RECOVERY UNIT

C2/C3 Recovery plant has been designed by Engineers India Limited. In this plant C2/C3 fraction of the feed gas is recovered under cryogenic conditions by Turbo Expander process. The C2/C3 product from this unit forms the feedstock of the gas cracker unit. The process comprises of the following section:

FEED GAS COMPRESSION:

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The sweetened gas is recovered from the Gas Sweetening Unit at 50 kg/cm2 and 40 C in the field gas Knock Out Drum where the entrapped liquids are removed. The gas is now compressed to 55 kg/cm2 in feed gas Expander compressor.

FEED GAS DRYING/REGENERATION:

The compressed gas is cooled down to 37 C using cooling water in Feed Gas Compressor discharge cooler and further down to 18 C by the outgoing lean gas in the feed/lean gas exchanger. The condensed moisture from the gas is removed in moisture separator. The gas is now saturated with water that is removed in a dryer to a water dw point of -100 C using molecular sieves as desiccants. There are two dryers out of which one is in drying mode and the other is either a standby or in regeneration mode. The drying period is around 12 hours and the regeneration is also 12 hours. A part of the lean gas from the first stage discharge of the lean gas compressors is heated to 320 C in a gas fired heater and this hot gas is used for regeneration of the dryers.

FEED GAS CHILLING/SEPARATION:

The feed gas enters the feed gas chiller #1 where it is cooled down to -32 C by the separator 1 & 2 liquids and the lean gas. The gas is further chilled down to -38 C in the demethaniser side reboiler. The gas is again chilled in feed gas chiller 1 to about -55 C to -60 C. The partially condensed feed gas at this stage is taken to the separator 1 where the condensed liquid is separated and sent to chiller 1 for cold recovery. The liquid is then fed to the demethaniser column.

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The uncondensed vapor from the separator 1 are cooled to -18 C by the outgoing lean gas in feed gas chiller 2. These vapours are now taken to Separator 2 where again the condensed liquid is separated. Cold from this liquid is recovered in feed gas chiller 1. It is then mixed with the Separator 1 liquid and this is fed to the demethaniser column on tray 18.

FEED GAS EXPANSION:

The overhead gas from separator-2 is expanded entropically in the feed gas expander to around 22 kg/cm2 and the temp of the gas drops to -98 C. Due to this chilling, there is further condensation of the gas. This vapour liquid mixture is fed to the demethaniser column on the 8th day .The work available from the isentropic expansion of the Separator-2 vapour is used to compress the feed gas.

FRACTIONATION:
The reaction consists of a demethaniser column which serves to recover C2-C3 product from (i) Separator 1 & 2 liquids received at -68 C and (ii) feed gas expander overhead vapours received at -98 C. This separates almost all the methane from the gas. It consists of 36 valve trays and one chimney tray for supplying feed to side reboiler. The column reboilers chill down the feed gas and in turn recover reboiler duty. The overhead vapours are chilled from -98 C to -102 C and condensed in the demethaniser overhead condenser by the cold gas from the demethaniser over expander outlet -117 C. The demethaniser overhead vapour is expanded from 21.5 kg/cm2 to 12 kg/cm2 and due to this gas is chilled to -117 C. This cold methane is the major source of refrigeration in the unit.The bottom product from the demethaniser column is the C2/C3 product, which is pumped as feed to cracker unit or sent to storage. The recovery of C2 is around 90%.

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LEAN GAS COMPRESSION:

The lean gas after giving away its cold to a series of exchanger (viz. Feed Gas Chiller-2, Feed Gas Chiller-1, Feed/Lean Gas Exchanger) gets heated to 25 to 30 C and is first compressed from 10kg/cm2 in the demethaniser overhead expander compressor and is further compressed to 55 kg/cm2 in a 2-stage gas turbine driven Lean Gas Compressor. It is cooled to 40 C and then sent back to HVJ pipeline. About 36 ton/hr of lean gas is drawn from first stage discharge of the lean gas compressor for dryer regeneration. This gas is then compressed to 55 kg/cm2 in a steam turbine driven Residue Gas Compressor and is then sent to Lean Gas Compressor discharge header. A part of gas from the first stage Lean Gas Compressor discharge is also taken for internal fuel consumption of the unit.

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GAS CRACKER UNIT(GCU)

The Gas cracker unit is a part of the U.P.Petrochemical complex. The Gas Cracker unit comprises of the Hot section (cracking furnace /cracked gas compressor) and Cold section (The Ethylene recovery unit). The C2/C3 hydrocarbon is cracked and compressed in Hot section and Ethylene, Hydrogen, Propylene, C4mix, C5+ are separated (distilled) in Cold section. Ethylene and Hydrogen are main product, where as Propylene, C4 mix and C5+ are separated as by products. The waste heat from the cracker gas effluent is used to produce VHP steam at 105 Kg/cm2 and 510OC, which is subsequently used for running the turbine of gas compressors and heat requirement of the GCU plant.The breaking of molecule to yield more useful products is called cracking. Cracking requires high temperature to initiate it and is endothermic. The heat is supplied by the direct firing of fuel gas in the furnace. Gas cracker Plant mainly consist of following units a) Furnace/ Quench Tower b) Cracked Gas drying c) Dispersed Oil Extraction process. d) Demethaniser
e)

Hydrogen unit (PSA)

f) De- ethaniser g) C2 Hydrogenation h) Ethylene Tower i) Ethylene Product Distribution j) DeButaniser k) Propylene Stripper

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FURNACES
The pyrolysis furnace area consists of four 24 W 144 type furnaces for 300,000 MTA ethylene capacity based on 8000 hours / year. The furnaces are both wall and floor fired and utilize gas fuels.As off- set connection section recovers waste heat from the flue gases leaving the radiant section of the furnaces. The fire gases are finally discharged to atmosphere via an induced draft fan and a stub stack. The cracked gases leaving the radiant coils are quenched in a series of exchangers before being routed to the quench water tower. The convection section of the pyrolysis furnaces contains the following services: a) Hydrocarbon (HC) Preheat - I. b) Boiler Feed Water (BFW) Economizer. c) HC Preheat II d) High Pressure Superheated Steam (HPSS). Hydrocarbon + Dilution Steam (HC + DS).

Process Description FEED VAPORIZATION:

C2/C3is received from C2/C3 recovery unit of GPU at 0 C and 22 kg/cm2 abs. It is flashed to around 10 kg/cm2 abs whereby it gets cooled at -26 C. It is then first heated by the propylene refrigerant and then by quench water and LP steam to around 80 C.

CRACKER FURNACE:

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Dilution steam is mixed with C2/C3 vapor in the ratio of 0.3:1 and fed to convection section of furnace. The dilution steam has two functions: a) Reduce the hydrocarbon partial pressure thereby increasing yield of ethylene. b) Reduce the rate of coke formation thereby increasing the furnace run length. In the convection section of furnace the feed gets heated to around 650 C by heat exchange with fuel gas. It is then fed to the radiant section of furnace where cracking of C2/C3 takes place. There are 5 furnaces each having capacity of 1,00,00 TPA. Each furnace has 12 W type radiant coils having total length of 44m. The temperature at the exit of the radiant coil is 850 C. the conversion per pass for ethane is around 75% by weight while that for propane is 93%. The hot gases are cooled to around 350 C by generating VHP steam in USX and TLX exchangers. It is further cooled to around 200 C in TLX-2 by heating boiler feed water.USX and TLX are heat exchangers.

QUENCH WATER AND DILUTION STEAM:

The hot gases are then quenched and cooled to around 40 C by direct contact with water in quench tower. Some light fuel oil present in cracked gas gets condensed. This is separated from water in oil water separator and pumped to off sites. The steam, which gets condensed in quench tower, is pumped to process water treatment unit to remove impurities such as oil and suspended solids. The treated water is pumped to dilution steam is generated and used in the process.

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CRACKED GAS COMPRESSION & DEHYDRATION:

The cooled cracked gas is compressed from 1.4 kg/cm2 abs to 26 kg/cm2 abs in a 4-stage steam turbine driven compressor having rated power of 18 MW. Inter stage/after stage coolers and KOD are provided to cool the compressed gas and separate the condensed liquid (fuel oil). H2S and CO2 present in cracked gas are removed in caustic tower between 3rd and 4th stages of compression. The cracked gas after the 4th stage is cooled by cooling water and propylene refrigerant and then routed to dehydrators where the moisture in cracked gas is reduced to <1ppm by volume

DEMETHANISER:
The dried gas is cooled in demethaniser section to around -100 C by different levels of propylene and ethylene refrigeration. It is further cooled to -135 C by vapors from expander compressor. The condensed liquids are fractioned in demethaniser system. The C2+ liquids are sent to deethaniser while the vapors (mainly CH4 and H2) are routed to expander where they are expanded from 21 kg/cm2 abs in a 3-stage machine. The vapors after giving cold in demethaniser section are compressed and routed to fuel gas system. The polybed Pressure Swing Adsorption (PSA) unit for hydrogen purification is designed to deliver a constant and continuous flow of high purity hydrogen product stream. PSA employs molecular sieve type adsorbent to purify the crude hydrogen stream supplied from demethaniser system. The adsorber operates on an alternating cycle of adsorption and regeneration with adequate beds always available for service.

ETHYLENE RECOVERY UNIT:

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In deethaniser, ethane/ethylene mixture gets separated from C3+. The ethane/ethylene mixture (top product from deethaniser) is fed to C2 hydrogenation section where acetylene is converted to ethylene/ethane by hydrogenation using palladium catalyst. The affluent from C2 hydrogenation is routed to green oil tower where green oil is removed by washing with cold ethylene. The overhead from green oil tower after passing through secondary dehydrator is fractioned in ethylene tower to separate ethylene and ethane. Ethylene tower has 116 trays and operates at a pressure of around 18 kg/cm2 abs to produce ethylene product of 99.8% by mole. A part of the ethylene (5%) is cooled and sent to cryogenic storage. From the remaining 95% ethylene, cold is recovered before sending it to downstream plant. The ethylene tower bottom supplies the ethane recycled to the cracking furnace.

PROPYLENE RECOVERY:
The bottom of the deethaniser is sent to depropaniser, which operates at 7.2 kg/cm2. In depropaniser, propane and propylene are recovered in mixture form. The propane/propylene mixture from the top of the depropaniser is fed to C3 hydrogenation system where methyl acetylene propadiene is converted to propane/propylene. The reaction takes place at temp 9-44 C and pressure of 16.417.4 kg/cm2 in C3 hydrogenation system. The propane/propylene mixture is then fractioned in propylene tower to give chemical grade propylene as top product and propane as bottom product. Propylene tower is maintained at a pressure of around 18 kg/cm2 and has 109 trays. The propane is recycled back to furnace.

BUTANE RECOVERY:

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The bottom product from depropaniser is routed to debutaniser, which operates at 4 kg/cm2. The overhead product is C4 fractions and bottom product contains C5 and heavier materials, which is sent to battery limit.

REFRIGERATION:
The plant has a 4-stage propylene refrigeration and 4-stage ethylene refrigeration. Propylene refrigerant compressor is designed to supply propylene refrigerant at -38.9 C, -24.4 C, -5.6 C and 7.2 C. The compressor is driven by condensing steam turbine. Ethylene refrigerant compressor is designed to supply ethylene refrigerant at four levels 100.6 C, -84.4 C, -67.8 C and -48.3 C respectively. The compressor is driven by a condensing steam turbine.

PROPYLENE REFRIGERATION SYSTEM

The Propylene refrigeration system will be put in normal operation as the first one of the three main compressors. C3R system will be utilized for cool down of the Demethanizer and it will be the single source of process refrigeration until C2R system start up. Propylene refrigeration system provides the initial chilling of gases down to 38.90C. Propylene refrigerant at different pressure pickup the heat from other streams generating propylene vapors at different pressures. Propylene refrigeration compressor compresses these vapors with discharge pressure of 17.5 kg/cm2, at which the propylene is condensed using cooling water. The liquid propylene is then flashed back, to provide chilling down to 39.2 0C in the circuit.

REFRIGERATION SYSTEM IN GCU

To get the desired products and by products of required purities from furnace effluents, it is required to be passed through a series of distillation columns after cracked gas is compressed and chilled adequately. The chilling is achieved by refrigeration system.

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Refrigeration system in GCU consists of Propylene refrigeration system (C3R) and Ethylene refrigeration system (C2R). C3R compressor is driven by backpressure cum condensing type turbine running using 105 kg/cm2g steam. C2R compressor is driven by condensing type turbine using 40 kg/cm2g steam. Four modes of operation for each of the refrigeration compressors were studied by the licensor SWEC. There are 2 different feed cases, referred to as Case 1 and Case2.There are 2 different chilled liquid ethylene product rates referred to as Case A and Case B. These two chilled liquid ethylene product rates are 24000TPA and 155000TPA respectively.

LPG UNIT
The objective of this unit is to recover Liquefied Petroleum Gas (LPG) and propane from Natural Gas (NG) and to provide C2/C3 feed stock to the existing Gas Cracker Unit (GCU).

PROCESS DESCRIPTION:

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Feed from GPU is fed at the 6th tray of C2/C3 column having 36 valve trays. Column is operated at a pressure of 22 kg/cm2. The column is designed to operate at a temp of 7.7 C at the top and 82.3 C at the bottom. Column top product is mainly C2, C3 and some percentage of C4 at a temp of -3 C which is transferred to C2/C3 storage or GCU by C2/C3 reflux and transfer pump and bottom product is C3+ which goes into LPG column for further fractionation. Top product C2/C3 vapor from C2/C3 column is condensed in the condenser by propylene refrigerant.

LPG COLUMN:
Bottom product C3+ from C2/C3 column is fed at 14th tray of LPG column having 54 valve trays. Column is operated at temp of 150 C and 15.5 kg/cm2. Temp at the top and bottom of column are 58 C and 130 C respectively. Operating pressure is 11 kg/cm2. Top product of the column is LPG vapor (C3, C4 and some C5), which goes into condenser where it is condensed by cooling water, which is being circulated in tubes. LPG product at 45 C is pumped to the LPG storage bullets by reflux and transfer pumps. Heat load is provided by MP steam at 16 kg/cm2. Now, bottom product goes into pentane column.

PENTANE COLUMN:
In pentane column, pentane and Spatial Boiling Point Solvent (SBPS) are recovered. Feed enters at 15th tray of column having 19 valve trays. Column is designed for a temp of 85 C and a pressure of 16.8 kg/cm2. It is normally operated at a temp of 42 C at the top and 66 C at bottom and a pressure of 14.2 kg/cm2. Top product of column is pentane vapor which goes into condenser where it is condensed by cooling water and then it is stored in the storage tank and part of condensed pentane is used as reflux in the column. Bottom product is SBPS, which is like petrol. Head load is provided by LP steam at 5 kg/cm2.

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PROPYLENE REFRIGERATION SYSTEM:

PRS has been provided in order to take care of chilling in LPG unit. Turbine, which is driven by VHP steam, produces MP steam & LP steam. MP steam is used in LPG bottom reboiler and LP steam is used in bottom reboiler of C2/C3 and of propane column. Mechanical work produced in this process is used to run compressor. Propylene liquid is used as cooling medium in C2/C3 over head condenser to condense the C2/C3 vapor. Propylene gets vaporized during the condensation process. Propylene vapor is fed to the Knock Out Drum (KOD-3). From KOD-3, it is fed to the suction of compressor at 4.8 kg/cm2 and -7.0 C and remaining propylene liquid is pumped into evaporator where it is converted into vapor and then transferred to KOD-2 and some liquid which is not vaporized goes into evaporator where it is converted into vapor and this vapor is fed to KOD-1. Vapor from KOD-1 at 1.4 kg/cm2 and -41 C is feed for suction-1 and it comes out from discharge-1 and D-1 goes into S-2 along with feed at 2.3 kg/cm2 and -28 C coming from KOD-2. This compressed feed comes from D-2 and goes into S-3 along with the feed from KOD-3. Now this compressed vapor coming out from D3 is routed to S-4 along with vapor at 8.7 kg/cm2 and 13 C from KOD-4. Final discharge from compressor is routed to condenser where propylene vapor is condensed by cooling water and then it is fed into accumulator at 40 C and 16.9 kg/cm2. From accumulator, it is routed to KOD-4 and then it is sent back to the C2/C3 condenser. Make up refrigerant is also provided because of loss in propylene during operation. Antisurge valves are provided to each KOD to avoid back flow.