Annexure-I

SUB: Brief description of the proposed facilities at Paradip Refinery

(PDRP)

1.0 INTRODUCTION

1.1 Objective

This document gives brief description of the Paradip Refinery Project, including
feedstocks, products, processing units and other connected facilities including
utilities and offsites.

2.0 EXISTING FACILITIES

2.1 Overview

Though the Paradip Refinery Project is essentially a grass-roots project,

nevertheless the project site has already seen some initial development in the
form of a crude oil tank farm, which was recently constructed within the refinery
boundary.

In addition, two other existing facilities - a nearby marketing terminal and a jetty
facility at Paradip Port Trust - are to be modified to accommodate the additional
feed and product movements which will result from the construction of the new
refinery complex. In paradip port a new south dock is proposed, to take care of
some of the PDRP Products throughout the year and crude unloading during
monsoon period when SPM-2 may not be operable due to bad weather. The
associated loading /unloading pipelines proposed to be laid in between southern
side of the refinery and proposed south dock complex.

These existing facilities are described in the following paragraphs.

2.2 Refinery Site and IOCL Pipelines Division Tank Farm

The site selected for the Paradip Refinery Project was previously scheduled as
the location for the 9 MMTPA Eastern India a refinery project refinery project - the
9 MMTPA Eastern India Refinery Project. Certain site preparation and civil works
were partially completed before this project was abandoned, including ground
improvements and the construction of some refinery roads, buildings, drains and
boundary walls.

Recently, a new IOCL Pipelines Division Tank Farm, comprising 18 crude oil
storage tanks, was constructed in the extreme south corner of the refinery plot
area. This tank farm is owned and operated by IOCL Pipelines Division. It is
proposed to receive and store crude oil imported from a Single Point Mooring
(SPM) via a sub-sea pipeline for subsequent transfer by pipeline to the Barauni
and
Haldia refineries. This use will continue in future though it will be interconnected
with additional crude storage tanks to be installed as part of the PDRP.

2.3 Marketing Terminal

The existing IOCL Marketing Terminal is located approximately 7 kilometers north

of the refinery site. The terminal receives oil products via pipelines from Paradip
Port - the route length of the pipelines is approximately 10.5 km. The IOCL
Marketing Terminal is located adjacent to two other terminals (belonging to BPCL
and HPCL) to which it is connected for the purposes of product transfer.
 The Terminal receives oil products imported via Paradip Port. These are stored in
the terminal and then loaded into road and rail tankers for despatch to customers.

The Terminal is to be further expanded in order to cater for the receipt of

products from the new refinery and to handle increased road tanker movements,
which will result from the implementation of the PDRP.

2.4 Paradip Port Trust

The Paradip Port Trust facilities are located at Paradip Port, approximately 11 km
north-east of the refinery site.

Paradip is one of the major Ports of India and is the main terminal for sea borne
trade in the area. The existing port facilities serve diverse industries including oil
products, fertilizers, metal ores, grains, and coal. The port also handles general
cargoes and containers and incorporates an integrated fishery harbour.

Indian Oil Corporation has recently installed a Single- Point Mooring (SPM-1)
approximately 20 km off the coast to allow import of crude oil from Very Large
Crude Carriers (VLCCS) via sub-sea pipeline directly to the new Pipelines
Division Tank Farm (note: this pipeline does not pass through the port area).
A second SPM (SPM-2) and sub sea pipeline is also proposed for crude
unloading for PDRP.

3.0 PARADIP REFINERY PROJECT (PDRP)

3.1 Overview

It is planned to implement the Paradip Refinery Project in two separate phases of

work:

Phase 1: Paradip, Refinery Project - The Phase-1 project involves construction

of a complete grass roots oil refinery and a first phase of petrochemical
production units, plus all related utility and offsites facilities and supporting
infrastructure. Crude oil processing capacity is 15 million tonnes per annum (15
MMTPA).

Phase 2: Naphtha Cracker Project - The Phase-2 project involves construction

of a naphtha cracker complex and associated utility and offsite facilities in future.
This is not a part of this write-up.

3.2 PDRP Phase 1 - Paradip Refinery Project

The Paradip Refinery Project involves the construction of an integrated

refinery/petrochemical complex designed to produce a range of distillate oil and
petrochemical products from 15 MMTPA of crude oil feedstock:

 LPG
 Kerosene
 Dual Purpose kerosene
 Naphtha
 Motor spirit
 High speed diesel
 Paraxylene
 Styrene
 Polypropylene
 Petroleum coke
 Sulphur

Total upgrading of the heavy oil components present in the crude oil feed is
accomplished within the refinery in Fluid Catalytic Cracking (FCC) and Delayed
 Coking units. Here, the heaviest distillate oils are mostly upgraded to diesel and
lighter products while excess carbon is rejected in the form of petroleum coke.
Any unconverted heavy oils are consumed as internal fuel oil within the refinery.

Sulphur is produced as a byproduct of the desulphurisation processes in the

refinery.

A listing and their respective process licensors and/or designers has been
described in section 4.

The PDRP also includes all associated utility, offsite and infrastructure facilities to
support the operation of the refinery complex.

 Complete utility facilities designed to meet the refinery’s demands for

cooling water, fuels, power, steam, water, instrument and plant air, inert gas,
etc.

 Offsite facilities including tankage for feedstocks plus intermediate and

final products as well as systems for import and export of feed and products
by various means including pipeline, road, rail and ship.

 Other offsite facilities including flare, effluent treatment, firewater, jetty

topsides, interconnecting piping and pipelines, etc.

 Infrastructure required to support the PDRP (e.g. roads, buildings, etc.).

3.3 PDRP Phase 2- Naphtha Cracker Project

Phase 2 of the PDRP is anticipated to be based around a naphtha cracker

complex with the aim of increasing the production of petrochemical products.

4.0 PROCESS LICENSORS AND DESIGNERS

The PDRP process units have been designed by technology providers according
to the following list.

Unit Designer / Licensor

‘Open-Art’ Units
Atmospheric Vacuum Unit (AVU) Foster Wheeler
Hydrogen Compression & Distribution (HCDS) Foster Wheeler
Sour Water Stripper (SWS) Foster Wheeler
Amine Regeneration (ARU) Foster Wheeler

Licensed Process Units

SR LPG Treater UOP
Naphtha Hydrotreater (NHDT) UOP
CCR Platformer UOP
CCR Regenerator UOP
Sulfolane UOP
Benzene / Toluene Fractionation UOP
Transalkylation (Tatoray) UOP
Xylene Fractionation UOP
Paraxylene Separation (Parex) UOP
Xylene Isomerisation (lsomar) UOP
Kerosene Treater (KTU) Merichem
Diesel Hydrotreater (DHDT) Shell Global Solutions
VGO Hydrotreater (VGO HDT) Axens
Fluid Catalytic Cracker (FCC) ABB Lummus / IOCL
Ethylene Recovery / Ethyl benzene / Styrene ABB Lummus
 Monomer (ER / EB / SM)
FCC LPG Treater Merichem
Propylene Recovery (PRU) Basell
Polypropylene (PPU) Basell
FCC Light Naphtha Treater Merichem
Delayed Coker (DCU) Foster Wheeler
Coker LPG Treater EIL
Alkylation (incl. Di-olefin Saturation) Exxon Mobil
Butane lsomerisation (Butamer) Exxon Mobil / UOP
Hydrogen Generation (HGU) Haldor Topsoe
Sulphuric Acid Regeneration (SAR) MECS
Flue Gas Desulphurisation (FGD) Cansolv

‘Package’ Units (LSTK basis)

Sulphur Recovery Units (SRU) Black & Veatch
Tail Gas Treating (TGT) Black & Veatch

5.0 FEEDSTOCKS

5.1 Crude Oil

The refinery will process imported crude oil. The selected potential crude oil feed
stocks are :

• Kuwait Export
• Maya
• Oman Export
• Ratawi
• Basrah Light
• Kuito

Refinery will have sufficient design flexibility to be able to process a range of

crude oil feedstocks at the design crude capacity of 15 MMTPA, and the following
cases were selected to represent the required design envelope:

Base crude case : Kuwait Export

Light/sweet crude case : 50% Oman Export / 50% Basrah Light

Heavy / sour crude case : 60% Kuwait Export / 40% Maya

In general terms, the sweet/light crude case determines the capacity of the upper
part of the crude distillation section within the AVU and of the downstream units
processing naphtha and lighter cuts, whereas the heavy/sour crude case sets the
design capacity for sections of the plant processing heavy cuts and residue.

5.2 Benzene

Benzene shall be partly imported to the refinery in addition to its own production
from aromatic block as supplementary feedstock for producing Ethylbenzene
(EB).

6.0 PRODUCT DEMANDS

The configuration of the Refinery and the capacities of the facilities is based on
the maximum product demand envisaged for domestic and export markets which
is given below.
 ‘000 tonnes per annum (KTPA)
Product

Domestic Export
LPG No limit Nil
Naphtha Nil 1501
Paraxylene 800 400
Styrene 300 300
Poly Propylene 450 400
MS Regular 100 Nil
MS Premium Nil No limit
DPK 870 800
HSD 821 No limit

Actual production rates resulting from the chosen refinery configuration are given
in Section 7.

7.0 REFINERY CONFIGUATION AND MATERIAL BALANCES

7.1 Introduction

The design of the process units is based on the following design feed cases.

 60% Kuwait Export / 40% Maya - to represent a “heavy sour” crude

blend design case
 50% Oman / 50% Basrah Light - to represent a “light sweet” crude blend
design case
 100% Kuwait Export - representative of ‘normal’ operation

In effect, the first two crude cases set the “design envelope” for the refinery.

The material balance for each of these cases is presented in the tables below;
data is presented on the following basis:

 Annualised basis (thousands of tonnes per annum, KTPA).

 Imported electric power.

 Steam boilers firing vacuum residue fuel (with FGD).

7.2 60% Kuwait Export / 40% Maya Crude Blend

The overall material balance is as follows:

FEEDS KTPA
Kuwait Export 9,000
Benzene import 66
Basrah 0
Oman 0
Maya 6,000
Total 15,066

PRODUCTS KTPA
LPG 675
Export Naphtha 459
Regular Gasoline 100
 Premium Gasoline 1,372
Domestic Kero 870
Export Kero 285
HSD (10 ppm S) - Domestic 821
HSD (10 ppm S) - Export 4,435
Coke 1,156
Polypropylene Domestic 450
Polypropylene Export 194
Paraxylene Domestic 800
Paraxylene Export 266
Styrene Domestic 300
Styrene Export 300
Sulphur Product 350
Refinery Fuel 2,106
Loss 127
Total 15,066

7.3 50% Oman / 50% Basrah Light Crude Blend

The overall material balance is as follows:

FEEDS KTPA
Kuwait Export 0
Benzene import 38
Basrah 7,500
Oman 7,500
Maya 0
Total 15,038

PRODUCTS KTPA
LPG 765
Export Naphtha 599
Regular Gasoline 100
Premium Gasoline 1,514
Domestic Kero 870
Export Kero 280
HSD (10 ppm S) - Domestic 821
HSD (10 ppm S) - Export 4,551
Coke 635
Polypropylene Domestic 450
Polypropylene Export 220
Paraxylene Domestic 800
Paraxylene Export 334
Styrene Domestic 300
Styrene Export 300
Sulphur Product 292
Refinery Fuel 2,119
Loss 88
Total 15,038

7.4 100% Kuwait Export Crude

The overall material balance is as follows:

 FEEDS KTPA
Kuwait Export 15,000
Benzene import 3
Basrah 0
Oman 0
Maya 0
Total 15,003

PRODUCTS KTPA
LPG 716
Export Naphtha 617
Regular Gasoline 100
Premium Gasoline 1,591
Domestic Kero 854
Export Kero 0
HSD (10 ppm S) - Domestic 821
HSD (10 ppm S) - Export 4,471
Coke 813
Polypropylene Domestic 450
Polypropylene Export 214
Paraxylene Domestic 800
Paraxylene Export 400
Styrene Domestic 300
Styrene Export 300
Sulphur Product 331
Refinery Fuel 2,150
Loss 75
Total 15,003

7.5 Nameplate Capacities for Process Units

7.5.1 Introduction

The nameplate capacities for individual process units have been determined
based on the annual material balances presented above plus consideration of
appropriate on-stream factors - for determination of stream-days - and design
margins - to allow for design uncertainties and operational flexibility.

7.5.2 Turnaround Frequency and On-stream Factor

The refinery is designed to operate continuously for a minimum period of five (5)
years between major turnarounds, albeit that some process units may require
‘interim’ shutdowns for catalyst regeneration, etc.

7.5.3 Unit Capacities

Unit capacities are presented in the table below and are quoted on an annualised
mass flow basis of feedstock.

Corresponding unit ‘nameplate capacities’ which reflect throughput per operating

day considering on-stream factors, etc., are defined in the design basis
documents for each unit.

Unit KTPA Capacity Basis

Atmospheric Vacuum Unit 15,000
SR LPG Treater 210
 Naphtha Hydrotreater 3,960
CCR Platformer 2,980
Paraxylene 1,200 PX product
Kerosene Treater 1,200
Diesel Hydrotreater 5,200
VGO Hydrotreater 5,400
Fluid Catalytic Cracker 4,170
FCC LPG Treater 1,850
FCC Light Cat Naphtha Treater 400
Alkylation / Butane Isomerisation 650 Alkylate product
Polypropylene 707 PP product
Styrene Monomer 600 SM product
Delayed Coker Unit 4,100
Coker LPG Treater 165
Sulphuric Acid Re-generation Unit 185 TPD
Hydrogen Generation Unit 72.8 Hydrogen product (Note A)
Anime Regeneration - Train 1 454.6 m3/hr Amine circulation
Amine Regeneration - Train 2 898.5 m3/hr Amine circulation
Sour Water Stripper - Train 1 397.7 m3/hr Sour water feed
Sour Water Stripper -Train 2 227.2 m3/hr Sour water feed
Sulphur Recovery Units 3 x 525 TPD Sulphur product
Tail Gas Treating Note B
Notes
A. Expressed as 100% hydrogen. The centralized hydrogen compression and distribution system
(HCDS) is designed to distribute 165.8 KTPA of hydrogen to consumers.
B. Tail gas treating (TGT) is part of SRU. TGT is configured as 2 x 100% trains.

8.0 REFINERY PROCESS UNITS

8.1 Atmospheric Vacuum Unit (AVU)

The AVU processes crude oil to produce a range of straight-run distillate products
plus vacuum residue intended for further processing within the refinery.

The AVU comprises a classical arrangement of three main distillation sections

which are designed as a single, integrated plant:

 Crude distillation section (CDU)

 Naphtha stabilisation section (NSU)

 Vacuum distillation section (VDU)

Primary separation of crude oil is achieved in the crude distillation section (CDU).
This section incorporates desalting to reduce the salt content of the crude oil. The
main products from the CDU are:

 A naphtha stream which passes to the naphtha stabilisation section for

further processing.

 Kerosene which is normally routed to the Kerosene Treating Unit, however

provision is made to route a portion to the Diesel Hydrotreating Unit in case of
high sulphur content.

 Atmospheric gas oils (light and heavy) which are combined and routed to the
Diesel Hydrotreating Unit.

 Atmospheric residue which is sent forward to the vacuum distillation section.

 The naphtha and lighter materials from the CDU pass to the naphtha stabilisation
section (NSU) where they are separated into products, namely:

 Sour fuel gas which is sent to fuel gas via amine treating.

 LPG which is first treated to remove H2S and mercaptans in a separate

SR LPG Treater unit before it is returned to the NSU section for splitting into
separate propane and butane products. The butane fraction is routed as
feedstock to the Alkylation unit and/or to LPG product storage. The propane
fraction is routed to LPG blending and product storage.

 Stabilised naphtha is sent to hydrotreating and/or product blending.

The vacuum distillation section recovers additional distillate materials from the
atmospheric residue feed by distillation under vacuum. The main products are:

 Vacuum diesel which is sent to Diesel Hydrotreating and/or to refinery

fuel oil blending.

 Vacuum gas oil which is sent to the VGO Hydrotreater.

 Heavy vacuum gas oil which is normally combined with VGO and sent to
VGO Hydrotreater but may be routed instead to the Delayed Coker in case of
high asphaltenes content.

 Vacuum residue, the bottom product, which is sent to the Delayed Coker
Unit.

The fuel gas treating section in the AVU receives sour waste gases from the AVU
and the Naphtha Hydrotreater Unit and treats them with amine solvent to remove
hydrogen sulphide (H2S) in order to produce sweet gas for blending into the
refinery’s fuel gas distribution system.

8.2 SR LPG Treating Unit

The Saturated LPG Treating Unit receives straight-run LPG from the AVU plus
LPG from the VGO Hydrotreater. This combined stream is processed in SR LPG
treating unit to remove H2S and mercaptans in an amine wash and caustic Merox
system. The treated LPG is then returned to the AVU for splitting into separate
propane and butane fractions.

8.3 Kerosene Treater Unit

The Kerosene Treater Unit (KTU) processes straight-run kerosene from the AVU
to produce a sweet kerosene product. The unit employs extractive mercaptans
oxidation technology.

8.4 Diesel Hydrotreater Unit

The Diesel Hydrotreater Unit (DHDT) processes straight-run gas oil (diesel)
streams from the AVU plus the Coker Light Gas Oil (CLGO) product from the
Delayed Coker unit and a portion of the Heavy Cat Naphtha (HCN) and Light
Cycle Oil (LCO) from the FCC Unit in order to produce an ultra low-sulphur diesel
product.

The primary product - high speed diesel (HSD) with max. 10 ppm wt sulphur
content - is routed to diesel product storage and blending. The unit also produces
a small naphtha by-product stream which is routed to the Naphtha Hydrotreater
Unit.
 Provision is also made within the DHDT for the co-processing of a portion of
straight-run kerosene from the AVU and for its subsequent recovery in an
adjoining kerosene splitter section. The flexibility to hydrotreat a portion of
kerosene in this manner enables the refinery to meet the total sulphur
specification for kerosene product when processing crude blends (e.g.
Kuwait/Maya) which have a high sulphur content.

8.5 VGO Hydrotreating Unit (VGO HDT)

The VGO Hydrotreating Unit (VGO HDT) pre-treats the vacuum gas oil feed to
the downstream Fluid Catalytic Cracker Unit (FCC) in order to reduce the sulphur
content of VGO sufficiently to satisfy downstream product quality requirements
and to minimise the sulphur dioxide content of flue gases emitted to atmosphere
from the FCC regenerator.

The feed to the VGO HDT comprises straight-run VGO from the AVU and Coker
Heavy Gas Oil (CHGO) from the Delayed Coker Unit.

The primary product from the VGO HOT is hydrotreated VGO containing less 600
ppm wt (max) sulphur; this stream is fed directly to the FCC unit for conversion.

A secondary product is a hydrotreated diesel cut (sulphur content 10 ppm wt

max.) which is routed to diesel product storage and blending.

Other by-products from the VGO HDT include:

 Off-gases - routed to the refinery fuel gas system.

 MP hydrogen-rich gas - routed to HCDS for recovery.

 LPG - routed to the LPG Treater and Splitter unit.

 Stabilised naphtha - routed to naphtha and gasoline product storage and

blending.

8.6 Fluid Catalytic Cracking Unit (FCC)

The Fluid Catalytic Cracking Unit (FCC) converts vacuum gas oil feedstocks into
more valuable lighter oil products and petrochemical feedstocks. The design of
the unit is primarily tailored to maximise the yields of ethylene and propylene for
use as feedstocks to downstream petrochemical production units. Cat cracked
naphtha is the main secondary product.

The main feedstock is hydrotreated vacuum gas oil received directly from the
VGO HDT. The unit also processes a small light naphtha by-product stream
produced in the Delayed Coker unit.

The FCC produces the following main products:

 Offgas - this stream is rich in ethylene. It is treated for the removal of H2S
and CO2 within the FCC unit before being routed as feedstock to the
Ethylbenzene/Styrene Monomer complex where the ethylene is recovered,
purified and then converted into styrene.

 Unsaturated LPG - this sour stream contains a proportion of propylene. It

is first routed for treatment to remove of H2S and sulphur compounds in the
FCC LPG Treater Unit before being sent as feedstock to the Propylene
Recovery / Polypropylene complex.
  Light cat naphtha - the LCN stream is a high octane gasoline blending
component. It is sent to the Light Cat Naphtha Treating Unit for sweetening
prior to rundown to gasoline storage and blending.

 Medium cat naphtha - the MCN stream is routed to the Naphtha

Hydrotreater Unit.

The FCC also produces a number of by-products:

 Heavy cat naphtha - HCN is routed to the Diesel Hydrotreating Unit

 Light cycle oil - LCO is routed either to refinery’s internal fuel oil system or
as feedstock to the Diesel Hydrotreating Unit.

 Clarified oil - this material is routed to the refinery’s internal fuel oil
system, or as feedstock to the Delayed Coker Unit.

8.7 FCC LPG Treating Unit

Unsaturated, sour LPG produced within the FCC unit requires treatment to
remove hydrogen sulphide (H2S), carbonyl sulphide (COS), carbon disulphide
(CS2) and mercaptan (R-SH) contaminants before it can be passed forward to
the Propylene Recovery / Polypropylene Units (PRU/PPU)

The FCC LPG Treatment Unit uses successive amine and caustic washes in a
classical ‘sweetening’ process to remove these sulphur bearing contaminants
from the LPG. The sweet LPG product is then routed to the PRU/PPU.

8.8 FCC Light Naphtha Treating Unit

FCC light cat naphtha requires treatment to remove mercaptans before it can be
sent for blending into the gasoline pool, therefore a FCC Light Naphtha Treating
unit is provided to sweeten the naphtha.

8.9 Alkylation and Butane Isomerisation

This section comprises two separate process units: a Sulphuric Acid Alkylation
Unit and a Butane Isomerisation Unit.

The Alkylation process is designed to produce a high-octane gasoline blending

component - alkylate - which will be used, via blending, to raise the octane
number of the refinery’s product gasoline pool. The unit incorporates a di-olefin
saturation (DIOS) section.

The main feedstocks to the unit are:

 Sweet, saturated C4 (primarily n-butane and isobutane) from the AVU.

 Sweet, saturated LPG (primarily propane, n-butane and isobutane) from

the CCR P!atformer Unit.

 Sweet, unsaturated C4 (primarily butylenes and isobutane) from the

Propylene Recovery Unit.

The Alkylation process is catalysed by sulphuric acid and achieves the chemical
combination of isobutane with the C4 olefins (butylenes) to form an iso-octane
rich alkylate product.

Because the LPG feed streams contain insufficient isobutane to alkylate all the
available olefins in the unsaturated LPG feed, a separate Butane Isomerisation
 Unit is included in the process scheme; this converts n-butane to isobutane and
hence satisfies the isobutane demand.

The primary product from the Alkylation and Butane lsomerisation unit is
stabilised, high-octane (96 RON) ‘alkylate’ which is routed to storage and/or to
gasoline blending.

Propane is recovered as a by-product stream and sent to LPG product storage

and blending.

The concentrated sulphuric acid catalyst is gradually degraded in the alkylation

process and a slipstream is continuously withdrawn, regenerated and returned to
maintain acid strength and purity. The acid regeneration is achieved in a separate
facility within the refinery.

8.10 Delayed Coker Unit (DCU)

The Delayed Coker Unit (DCU) upgrades vacuum residue feedstock received
from the AVU to produce a range of cracked, distillate oil products which, after
further refining in downstream units, are suitable for blending into final products
and/or as petrochemical feedstocks. Delayed coking is a thermal cracking
process and excess carbon is rejected in the form of petroleum coke which is
produced in significant quantities.

The feed stream to the DCU is vacuum residue produced in the vacuum
distillation section of the AVU. In addition, to enable the refinery to process heavy
crude oils with a high asphaltenes /metals content, provision is made for the
heaviest side cut (HVGO) from the vacuum distillation column to be blended in to
the DCU feed. This provides the refinery with a convenient means of limiting the
asphaltenes (and/or metals) content of the VGO feedstock sent forward to the
VGO Hydrotreater within acceptable limits; the impact on the DCU operation is
insignificant.

The DCU produces a range of cracked distillate products which are routed as
follows:

 Fuel gas - this is sweetened within the DCU and then routed to the
refinery fuel gas system.

 Coker LPG - this is routed via the Coker LPG Treating Unit to the
Propylene Recovery / Polypropylene Unit.

 Coker light naphtha - this is routed to the FCC unit.

 Coker heavy naphtha - this is sent as feedstock to the Naphtha

Hydrotreater Unit.

 Light coker gas oil / coker diesel - LCGO is routed as feedstock to the
Diesel Hydrotreater Unit.

 Heavy coker gas oil - HCGO is routed as feedstock to the VGO

Hydrotreater Unit.

The other main product from the DCU is petroleum coke. This is conveyed to a
coke storage and handling area prior to despatch to external customers.

8.11 Coker LPG Treating Unit

Unsaturated, sour LPG produced within the Delayed Coker Unit requires
treatment to remove hydrogen suiphide (H2S), carbonyl sulphide (COS), carbon
 disulphide (CS2) and mercaptan (R-SH) contaminants before it can be passed
forward to the Propylene Recovery / Polypropylene Units (PRU/PPU).

The Coker LPG Treatment Unit uses amine and caustic washes in a classical
‘sweetening’ process to remove these sulphur bearing contaminants from the
LPG. The sweet LPG product is then sent forward to the PRU/PPU.

8.12 Hydrogen Generation Unit (HGU)

The Hydrogen Generation Unit (HGU) utilises steam-methane reforming of

hydrocarbon feedstock to produce a hydrogen-rich gas product which is purified
in a Pressure Swing Adsorption unit(PSA unit) to yield hydrogen with a minimum
purity of 99.9 mol% hydrogen.

The HGU operates in turndown mode during normal refinery operation because
the majority of the hydrogen demand is satisfied by hydrogen production from the
Platformer. Maximum demand for hydrogen from the HGU occurs during a
shutdown scenario in which the CCR Platformer is shutdown, but the Diesel
Hydrotreater, VGO Hydrotreater and Polypropylene units continue in operation at
50% turndown.

The preferred hydrocarbon feedstock to the HGU is the ‘raffinate’ by-product

stream from the Sulfolane Extraction process in the Aromatics complex.
However, provision is made for the unit to accept other sweet naphtha streams
and LPG as alternative feedstocks. Natural gas is also foreseen as a potential
future feedstock and limited provisions are made in the HGU design to facilitate a
future introduction of NG feed.

Hydrogen products from the Platformer and HGU are routed to a centralised
Hydrogen Compression and Distribution System (HCDS) which serves the
refinery.

8.13 Hydrogen Compression and Distribution System

Hydrogen treat gas used within the refinery is derived from two main sources:

 The CCR Platformer Unit (which provides a base load supply during
normal operation)

 The Hydrogen Generation Unit (which supplies the balance to satisfy total
demand)

Both of these streams are routed to the Hydrogen Compression and Distribution
System (HCDS).

The HCDS also receives hydrogen rich off-gases from the Styrene Monomer and
VGO Hydrotreater units these streams contain sufficient hydrogen to warrant
recovery and a small PSA section is employed for this purpose.

The various purified hydrogen streams (minm. purity 99.9 mol%) are then
combined and distributed to all hydrogen consuming units within the refinery.
Three distribution pressure levels (LP/MP/HP) are provided to align with user
requirements: the two higher pressure levels are achieved via a two-stage
compression system.

The hydrogen distribution pressures are set to eliminate the need for separate
hydrogen make-up compressor systems within any of the consuming units.

8.14 Sour Water Stripper Units (SWS)

 Sour waters produced within the refinery complex are treated to remove
contaminant hydrogen sulphide and ammonia in the sour water stripper units.
The sour gases (hydrogen sulphide and ammonia) recovered from the sour water
streams are routed to the sulphur recovery unit for recovery of elemental sulphur.

The sour water stripper is configured as two separate trains in order to segregate
the treatment of sour waters from different sources; the routings of the most
significant sour water streams are indicated in the table below:

SWS Train 1 SWS Train 2

(Phenolic) (Hydroprocessing)

AVU Naphtha HDT

FCC Diesel HDT

DCU VGOHDT

SWS Train 1 will process sour water streams from the other process units. Some
of these streams will be contaminated with traces of phenols, cyanides and other
contaminants which are by-products of thermal cracking reactions. Re-use of
stripped water from these sources within the hydroprocessing units is to be
avoided; instead it is preferred to route these stripped waters as wash water for
desalting since this provides an opportunity for phenols and cyanides to be re-
absorbed into crude oil, thus minimising the duty of the effluent treatment plant.

SWS Train 2 will process ‘clean’ sour waters from the hydroprocessing units and
other units which do not involve thermal cracking reactions. These sour waters
are relatively ‘clean’ - they contain minimal other contaminants - and, after
stripping, are suitable for partial recycle for use as wash water within the
hydroprocessing units.

The two sour water stripper units will operate in segregated mode; however, they
shall be interconnected to provide a limited degree of load sharing in case one
unit is required to shutdown for emergency maintenance.

8.15 Amine Regeneration Units (ARU)

Lean amine solvent (DEA) is used in absorber and extractor columns within the
refinery to remove hydrogen sulphide from gas and LPG streams. Carbon dioxide
is also scrubbed from FCC off gases fed to the EB/SM unit. The rich amine
solvent is returned to a centralised amine regeneration system where hydrogen
suiphide gas is recovered and routed to sulphur recovery and regenerated lean
solvent is recycled to users.

The Amine Regeneration system is configured as two separate trains in order to

segregate the amine solvent which has contacted ‘cracked’ streams originating in
the FCC and Coker (Train 1) from amine which is used within the main
hydroprocessing units (Train 2).

The two-amine regeneration units will operate in segregated mode; no inter-

connections are provided.

8.16 Sulphur Recovery Units (SRU) and Tail Gas Treating (TGT)

The Sulphur Recovery Unit (SRU) takes acid gas feed from the ARU , SWS and
SO2 rich stream ex FGD and converts hydrogen sulphide (H2S) into elemental
sulphur using a modified version of the classic Claus sulphur recovery
technology. The SRU is also equipped with sulphur degassing systems and
amine-based Tail Gas Treating (TGT) units in order to achieve a very high
percentage recovery of sulphur present in the acid gas feeds. Tail gas
incineration is used to convert residual traces of H2S in the tail gas into SO2.
 Ammonia present in the acid gas feed from the SWS is destroyed in the burners
of the SRU.

The SRU is configured as 3 x 50% units in order to provide a very high availability
factor. The TGT section and tail gas incinerators are each configured as 2 x
100% units for the same reason.

Feed streams to the SRU are acid gases from the Amine Regeneration Units,
and sour gases from the Sour Water Stripper units, plus sulphur dioxide from the
Flue Gas Desulphurisation unit.

Sulphur product is exported in both liquid and solid (granular) forms.

8.17 Sulphuric Acid Regeneration Unit (SAR)

Concentrated sulphuric acid is used as a catalyst within the Alkylation Unit. The
acid is slowly degraded in the alkylation process so a continuous purge of spent
acid is removed and sent for regeneration in an on-site regeneration facility.

The Sulphuric Acid Regeneration Unit processes the spent acid to produce a
regenerated acid stream which is returned to the Alkylation unit. The process
involves thermal decomposition of the spent acid to sulphur dioxide, then
conversion to sulphur trioxide and back into sulphuric acid.

9.0 PETROCHEMICAL PROCESS UNITS

9.1 Aromatics Complex

The Aromatics Complex comprises the following process units.

 Naphtha Hydrotreater (including naphtha fractionation)

 CCR Platformer
 CCR Regenerator section
 Sulfolane
 Benzene / Toluene Fractionation
 Transalkylation (Tatoray)
 Xylene Fractionation (incl. Reformate splitter)
 Paraxylene Separation (Parex)
 Xylene Isomerisation (Isomar)

Incoming naphtha feeds (full range naphtha from the AVU plus naphtha streams.
from the FCC and Coker and a small benzene/toluene stream from the EB/SM
unit) are pre-treated in the Naphtha Hydrotreater and then fractionated into three
separate hydrotreated naphtha products. The light and heavy cuts are sent to
naphtha/gasoline blending while the heart-cut is fed forward via the CCR
Platformer into an integrated arrangement of classic aromatics units.

The primary products from the aromatics units are:

 Paraxylene - sent to product tankage

 Benzene - an intermediate product which is subsequently consumed as

feedstock for the Ethylbenzene/Styrene Monomer complex.

 Excess A9/A10 aromatics stream from Xylene fractionation - sent to

gasoline blending.

By-products include:
  A raffinate stream from the Sulfolane unit - used as preferred feedstock to
the Hydrogen Generation Unit or as a gasoline blending component.

 A heavy aromatics stream from Xylene fractionation - to refinery fuel oil.

 A hydrogen-rich gas stream from the Platformer PSA unit which is routed
to the refinery’s Hydrogen Compression and Distribution System.

9.2 Ethylene Recovery / Ethylbenzene / Styrene Monomer Unit (ER / EB/ SM)

The EB/SM complex converts benzene and ethylene feedstocks into styrene
monomer product. There are three main elements to the process scheme:
ethylene recovery and purification, ethylbenzene production and styrene
monomer production.

The feedstocks are 1) sweet ethylene-rich gas from the FCC unit and 2) benzene
either directly from the benzene fractionation section within the Aromatics
complex or imported benzene from storage.

The EB/SM complex produces a single main product - styrene monomer - which
is routed to product storage.

By-products comprise a small benzene/toluene by-product stream is routed back

to the Aromatics complex, a hydrogen-rich offgas stream which is routed to the
HCDS for hydrogen recovery, and off gases which are routed to fuel gas.

9.3 Propylene Recovery & Polypropylene Units (PRU/PPU)

The Propylene Recovery Unit (PRU) and Polypropylene Unit (PPU) receive
treated, unsaturated LPG feeds from the FCC and the Delayed Coker units. The
propylene content is first extracted and purified to yield propylene in the PRU
section. The propylene is then fed forward into the polypropylene unit for
manufacture of homopolymer polypropylene product.

The unsaturated LPG feed streams containing propylene are derived from the
FCC Unit and the Delayed Coker Unit. Both feed streams are pre-treated for
removal of H2S, COS and mercaptans, etc. in upstream LPG Treating units. The
polypropylene process also consumes hydrogen gas, which will be supplied from
the Hydrogen Compression and Distribution System.

The primary product from the PRU/PPU is polypropylene homopolymer.

However, the PPU design includes provisions for a future upgrade to allow the
production of random copolymer, terpolymer and impact copolymer at a later
date.

Each polypropylene product is capable of being produced in different grades

according to the end-use. End-uses for homopolymer include injection moulding,
blow moulding, thermoforming sheet, tape/raffia, fibre and films.

The PRU/PPU also produces a number of by-products:

 Propane from PRU section - routed to LPG product storage.

 Unsaturated C4s from PRU section - routed to Alkylation Unit and/or to

LPG product storage.

 Offgas from PPU section - routed to fuel gas system.

10.0 OFFSITE SYSTEMS

10.1 Crude Oil Import, Storage, Blending and Pumping

Crude oil is imported to the refinery by marine tankers. Normally, crude oil is
proposed to unload from Very Large Crude Carriers (VLCC) via an existing SPM
and sub- sea pipeline (operated by IOCL) into new crude oil storage tanks
located within the, refinery. A second SPM and sub-sea pipeline are to be
installed to increase crude handling capacity. The onshore pipelines from the two
SPMs will be interconnected to provide flexibility for import of crude from either
SPM to either of the crude tank farm ..

However, to cater for periods when the SPM cannot be used due to bad weather,
provision is made for crude oil import by a new crude pipeline from crude tankers
moored at the new southern jetty at Paradip Port.

10.2 Intermediate and Finished Product Storage, Blending and Pumping

Storage and transfer facilities are provided for some intermediate and all finished
liquid products produced within the refinery complex. Materials to be stored and
handled include oil products (ranging from LPG through to vacuum residue) plus
petrochemical products such as Benzene, Paraxylene and Styrene. Other
materials to be stored and handled include internal fuel oil and various slop oils.
Solid products and sulphur.

In-line blending of component rundowns from individual units into final product
tanks is used to achieve required finished product specifications; this applies
particularly to gasoline and diesel products.

The required storage volumes for finished products are based on despatch
volumes and other factors. The storage capacities for intermediate products are
based either on licensors recommendations or determined based on the refinery
shutdown philosophy.

Pumping capacities for final products are based on despatch requirements

determined by the destination - the marketing terminal, the jetty, or direct to road
tankers - as appropriate. Transfer rates for intermediate products are determined
by process requirements.

10.3 LPG Refrigerated and Pressurized Storage

LPG is to be stored in pressurized form in mounded bullets and refrigerated in

atmospheric storage tank. Refrigerated LPG is to be dispatched through ship
from port and pressurized LPG through road tanker from refinery. Facility also to
be provided for transfer pressurized LPG to Marketing Terminal.

10.4 Sulphur Storage, Handling, Forming and Despatch

Liquid sulphur is produced by the Sulphur Recovery Units and routed to liquid
sulphur storage tanks prior to despatch by pipeline and/or road tankers to nearby
customers. Provision shall also be made to produce a solid granular sulphur
product.

10.5 Polypropylene Storage and Transfer

Solid polypropylene product - in pellet form - is produced in the Polypropylene

unit. The polypropylene storage and transfer system receives the raw product
and prepares batches of homogenised polypropylene product for storage in bulk
silos. The homogenised product is then either bagged and palletised for despatch
by truck, or conveyed into bulk containers for export by sea.

10.6 Marketing Terminal and Jetty Systems

 The following provisions are made for transfer/export of liquid oil products from
the refinery:

 By pipelines to jetty - the majority of liquid products are despatched by

pipelines to new marine loading facilities at Paradip Port.

 By pipelines to IOCL Marketing Terminal - small proportions of liquid

products (LPG, HSD, Kerosene, DPK and MS) shall be sent by separate
pipelines to the existing IOCL Marketing Terminal for subsequent despatch
by road and rail.

 By inland pipelines - piping connections within the refinery shall be

provided to enable HSD, DPK and MS products to be transferred directly to
inland pipelines operated by IOCL Pipelines Division.

 By road truck - Provision shall be made for dispatch LPG, Coke,

Polypropylene, Sulphur & Benzene by road from the refinery.

10.7 Flare & Blowdown Systems

The refinery flare and Blowdown system collects and safely disposes of liquid
and gaseous releases from the refinery complex. The peak release rates occur
as a result of abnormal and emergency situations which may affect the whole
refinery (e.g. power failure), but the system also handles small continuous
releases of waste materials arising from normal operation.

Several separate flare collection and disposal systems are provided for the
refinery complex in order to segregate releases based on consideration of origin
(composition), pressure and flowrate.

Gaseous releases are burnt at the flare tip; liquid releases are collected in knock-
out drums and returned for recovery. A brief description on flare and blow down
system is attached as Annexure-I

10.8 Effluent Treatment

Waste water streams arise in the refinery from a number of different sources,
including process operations, maintenance, rainfall and sanitary waste. The
waste water streams are normally segregated at source according to their origin
These wastewaters then pass separately to the Effluent Treatment Plant where
treatment occurs according to the particular need. Typical treatment steps include
oil separation, neutralisation, bio-treatment, solids removal and water recovery. In
order to minimise the refinery’s demand for fresh water from external supplies, as
much treated effluent water as possible is recycled for re-use within the refinery.
The residual reject water is disposed off to sea via an outfall.

10.9 Oily Spent Caustic Treatment

Wet air oxidation is used to treat oily spent caustic streams arising from refinery
operations. The treated stream is discharged to the Effluent Treatment Plant.

10.10 Waste Disposal

Various liquid and solid wastes arise from the operation of the refinery complex,
including spent catalysts, ETP sludge, waste oils, used filter cartridges, ash,
municipal waste and other waste materials. The treatment and disposal of these
waste materials shall be carefully managed.

10.11 Wastewater Drainage and Collection System

 Several separate wastewater drainage systems are provided in order to allow
segregation at source of wastewaters arising from different sources. Segregation
is made according to the anticipated composition of the water. Such segregation
allows the routing of different waste water streams to appropriate treatment steps
within the effluent treatment scheme. Individual drainage and collection systems
comprise sewers, collection ponds, sumps and transfer pumps.

10.12 Fire Protection System

The fire protection system for the refinery complex includes automatic fire and
gas detection systems at appropriate locations within the refinery plus various fire
fighting facilities. The latter includes firewater supply and distribution systems,
foam systems, carbon dioxide systems, fixed and mobile fire fighting equipment.
Safety equipment, fireproofing and fire training facilities are also specified. Details
Fire Protection Facilities is enclosed as Annexure-III .

10.13 Coke Handling and Despatch System

Petroleum coke is produced in substantial quantities in the Delayed Coker Unit.

Coke dewatering, crushing and sieving will be accomplished on-plot within the
DCU battery limit. The coke is then transferred by conveyor to be stored within
the refinery in open coke piles before it is loaded into trucks.

The coke handling and despatch facilities include the coke stockpiles with their
associated stacker and declaimer systems plus all necessary coke hoppers,
conveyors, silos, and truck loading systems. Facilities are also required to
suppress dust and to handle contaminated water run-off from the coke piles and
coke handling areas.

10.14 Catalyst and Chemicals Storage and Handling

The catalyst and chemicals storage and handling system handles the supply of
catalyst and chemicals used within the refinery complex.

Most of the refinery and petrochemical process units employ catalysts to promote
reactions and/or absorbents to remove impurities; most of the materials
employed are solids. The catalyst handling system is required to manage
supplies of a large number of different catalysts and absorbents, including any
associated support media (e.g. inert balls). The system handles both the receipt
and storage of fresh materials and the disposal of spent materials. Reserve
stocks of catalysts and absorbents are held in a warehouse according to the
process requirements.

Similarly, many process, utility and offsite systems employ specific chemicals;
examples include anti-foam, corrosion inhibitor, amine, DMDS, lubricating oils,
etc. Many of these materials are handled in liquid form, though others may be
solids (e.g. activated carbon) or gases (e.g. ammonia). The chemicals storage
and handling system manages the supply of these materials to users. Reserve
stocks are held in a warehouse.

11.0 UTILITY SYSTEMS

11.1 Raw Water Receipt and Treatment

The fresh water requirements of the refinery complex are met by extracting river
water from the Mahanadi River at Cuttack and transporting it to the refinery site
by pipeline. The facilities at Cuttack include water lift, pre-settlement and
pumping systems.
 The raw water receipt and treatment system at the refinery handles the receipt,
storage and treatment of raw river water to produce a treated water supply to
consumers within the refinery. The system includes raw water reservoirs, water
treatment systems, clarified water reservoirs and all associated transfer and
supply pumps.

Uses for treated water include the following:

 Feed to demineralised water plant

 Make-up to cooling water system

 Supply to service water system

 Supply to drinking water system

 Supply to firewater system

11.2 Demineralised Water System

The demineralised water system receives treated raw water feed and recovered
water from ultra-filtration, and produces demineralised water for supply to the
refinery’s boiler feed water system and other consumers.

The system comprises a reverse osmosis plant, mixed bed demineralisation

polisher and demineralised water storage. System capacity is determined based
on make-up requirements to the BFW system and other minor consumers, after
taking account of condensate recovery.

11.3 Drinking and Service Water System

Treated water from the raw water treatment system is used as make-up to the
drinking and service water systems.

The service water system takes treated raw water for supply to hose stations, etc.
by dedicated service water pumps and a distribution pipe network. Water for
gardening is also supplied from this system.

Drinking water shall be supplied to the refinery complex and its township. Treated
raw water used for drinking is chlorinated and then distributed to consumers via
dedicated pumps and a distribution pipe network.

11.4 Recirculating Cooling Water System

Fresh cooling water is supplied to consumers within the refinery.

A recirculating system is employed, complete with cooling towers, pumps and

distribution piping. Four separate dedicated systems/networks are provided; the
allocation of process and other consumers to each network is based on
geographical and logistical considerations.

Treated raw water is used for make-up to replace blowdown and evaporative
losses. Chemical treatment is used to inhibit biological growth, fouling and
corrosion.

11.5 Steam, Condensate & BFW System

The primary purpose of the steam, condensate and BFW system is to supply
steam to meet the refinery demand. The system comprises of the following main
elements:
  Deaerators for BFW preparation from demineralised water feed.

 HHP Steam generation in dedicated boilers fired by high-sulphur residual

fuel.

 Steam letdown and HP/MP/LP distribution systems.

 Condensate recovery and conditioning system.

Steam is variously used by process consumers (eg. for stripping steam and
process heating), in steam turbines, for atomisation of fuel oil, and for general
heating and tracing.
The steam demand of the refinery is met primarily by the generation of HHP
steam in fired boilers. HHP steam is then let-down to other users levels
(HP/MP/LP) via an optimum combination of back pressure turbines and let-down
stations. Steam generated from waste heat within the process units is used to
augment these supplies.

The steam generation system includes associated boiler feed water (BFW)
deaerator and chemical dosing systems. Demineralised water and polished
condensate are fed to the BFW section which prepares de-aerated and treated
BFW for use in the CPP plus other waste heat boilers and process steam
generators. BFW is distributed to consumers at two pressure levels, HP and MP,
according to the user requirements

The steam boilers are configured on an N+2 basis to ensure adequacy of supply
when one boiler is shutdown for maintenance and another is shutdown due to
failure.

The boilers are fuelled by heavy residual fuel (vacuum residue + cutter stock) and
employ flue gas desulphurisation (see below) to limit S02 emissions to
atmosphere.

Condensate collection systems (operating at HP, MP, LP and LLP pressure

levels) collect steam condensate from producers. Separate collection systems
are required for clean condensate and suspect condensate. Suspect condensate
undergoes a ‘polishing’ treatment prior to re-use as BFW. The BFW deaeration
and chemical treatment systems are part of the CPP.

11.6 Gas Turbine Generators

The major part of the refinery’s electrical power demand is met by power import
via overhead transmission lines from external generation facilities (Tata JV).

However, this supply is augmented by on-site power generation using gas turbine
generator sets fuelled by distillate fuel (primarily naphtha).

On-site power generation capacity is approx. 60 MW. In normal operation the

GTG sets will operate to supplement imported power. In case of loss of imported
power, then the GTG sets will provide emergency power for the operation of
essential plant and to facilitate the safe shutdown of the refinery.

Heat recovery steam generators (HRSG) are also provided in the gas turbine
exhausts to maximise efficiency.

11.7 Flue Gas Desulphurisation

Flue gas desulphurisation is provided for the steam boilers in order to minimise
sulphur dioxide emissions due to the combustion of residual fuel in the boilers.
 The flue gas desulphurisation system utilises a circulating solvent to scrub
sulphur dioxide from the flue gases. The sulphur dioxide released from the
solvent regeneration facilities is fed to the Sulphur Recovery Facilities for
recovery of elemental sulphur.

11.8 Plant and Instrument Air System

Compressed air is used in the refinery as plant air, service air and instrument air.

Atmospheric air is raised up to system pressure by motor driven air compressors.

Plant and service air is distributed directly to users via a header network.
Instrument air requirements are met via a dedicated air dryer system and
instrument air header network.

To facilitate safe refinery shutdown in case of general power failure, a reserve

supply of air is held in a dedicated HP air receiver; this supply is released to the
instrument air dryers if system pressure declines.

11.9 Nitrogen Generation System

Inert nitrogen gas is typically used in the CCR catalyst regeneration unit and for
various blanketing and purging duties during normal operation, also for system
pressurisation and purging during start-up and shutdown.

A cryogenic nitrogen generation unit (air separation plant) is provided to generate

both gaseous and liquid nitrogen to support normal plant operation. Nitrogen gas
is distributed to users via a distribution network. Liquid nitrogen is rundown to the
liquid Nitrogen storage facility.

The liquid nitrogen storage facility holds a reserve of liquid nitrogen which is
vaporised and used to meet intermittent peak nitrogen demands which arise
during start-up, shutdown, catalyst regeneration, etc. This system also provides
an independent, continuous supply of nitrogen gas to the CCR section of the
Platformer unit as required by the process licensor. The liquid nitrogen system
design also provides for the import of liquid nitrogen from road tankers to
supplement supplies during periods of high demand.

A high-pressure cryogenic liquid nitrogen pump and vaporiser system is provided

to enable pressuring of the VGO HDT unit for leak testing with nitrogen at startup.

11.10 Fuel Gas and Fuel Oil Systems

Fuel Gas

Waste gas streams (off-gases) produced within refinery are collected for use as
refinery fuel gas within fired heaters, boilers, etc. Amine scrubbing facilities are
provided within the process units to ensure that any potentially sour streams are
scrubbed to remove H2S before entering the fuel gas system.

The fuel gas system comprises a collection header network, fuel gas mixing drum
and a distribution header network. An LPG vaporiser is provided to allow fuel gas
supplies to be supplemented by vaporised propane / LPG during startup and
normal operation.

Fuel gas, being a clean waste gas stream, is the preferred source of low sulphur
fuel in the refinery. It is burnt preferentially in fired heaters within the process
units. However, there is insufficient fuel gas available to meet the refinery fuel
demand so fuel oil is used as a supplementary fuel.

Fuel Oil

Three separate liquid fuel supply systems are provided:

  low-sulphur naphtha/diesel fuel supply to gas turbines

 low-sulphur fuel oil supply to process furnaces

 heavy high-sulphur fuel oil supply to steam boilers

Due-to SO2 emission restrictions, only low sulphur fuel oil components can be
utilised without the provision of flue gas desulphurisation facilities.

The gas turbine generators (GTG) are normally fuelled by a blend of low sulphur
naphtha by-products derived from the aromatics complex, with diesel as a
backup fuel supply.
The low sulphur fuel oil used in process furnaces is a blend of LCO and clarified
oil from the FCC unit plus heavy aromatics from the Aromatics complex. Diesel
product is used to supplement the supply as necessary.

A separate heavy fuel oil system is provided for the steam boilers. This system is
fed mainly by vacuum residue from the AVU. Flue gas desulphurisation is
provided for the boiler plant to limit atmospheric emissions of sulphur dioxide.

11.11 Flushing Oil System

The flushing oil system supplies gas oil (diesel) as a flushing medium to
instruments and pump seals during normal operation, as well as providing a
means of flushing lines and equipment containing heavy/waxy hydrocarbons
during preparations for maintenance.

The system comprises a storage tank and pump plus associated distribution
piping network.

12.0 ENVIRONMENTAL DESIGN BASIS

All emissions to the environment shall meet national regulations, local

environmental requirements, and project-specific environmental conditions.
These environmental design requirements are

 Emissions to air - a SO2 emission cap of 1,000 kg/hr for the whole
complex.

 Discharges to sea - a cap on the quantity and quality of process effluent

discharged to the sea.

 Solid waste - an on-plot landfill site for the disposal of solid waste
generated by the project.

13.0 REFINERY SHUTDOWN PHILOSOPHY

A refinery shutdown philosophy has been prepared to define the manner in which
individual sections of the refinery can be shutdown for maintenance and/or major
turnaround. Operating strategies to be adopted in case of emergency shutdown
situations are also described.

In summary, the refinery is planned to be shutdown for a major turnaround every

5 years, with intermediate, partial shutdowns for catalyst replacement or
regeneration as necessary.
The philosophy for major turnarounds, on a 5 year cycle, is that the entire
processing complex will be shutdown at one time for maintenance.

14.0 INSTRUMENTATION SYSTEM

 Refinery operations are controlled from several locations:

 One central process control room caters for the process units.

 A separate control room is provided for the utility facilities.

 One ‘Oil Movements and Storage (OM&S) control room deals with crude
receipt and blending, plus dispatch of liquid products

 A separate control room is provided for the Effluent Treatment Plant.

 A Jetty Control Room is expected to be provided at Paradip Port

A Distributed Control System (DCS) provides regulatory control for all facilities,
using Foundation Fieldbus for monitoring and for non-critical control loops and
conventional hardwired systems for critical control loops.

Other ‘specialised’ instrumented control systems include process compressors

controls, controls for turbine driven generator sets, burner management systems,
machinery monitoring systems and custody transfer metering.

15.0 ELECTRICAL SYSTEM

The primary source of electric power for the refinery complex is power imported
from a new power plant to be built in joint venture between Tata Power Company
and IOCL. The new power plant will be located at Naraj Marthapur, located
approximately 120 km from Paradip.

Imported power is supplemented by on-site gas turbine driven power generators.